Light Guide Plate Light Entrance Structure Layer Segmentation
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Solution Overview
Problem
Conventional light guide plates with microstructures formed by injection molding face challenges in controlling injection pressures as display surface dimensions increase, leading to unsatisfactory product quality.
Innovation Solution
A light guide plate design featuring a plate body with an optical adhesive layer and a light entrance structure layer, where the light entrance structure layer includes a substrate with a light-cured or thermal-cured structure, formed by distributing and curing curable material on a substrate, and attaching an optical adhesive layer to the plate body's light entrance surface to prevent light convergence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If microstructures are integrally formed on the light guide plate by injection molding methods, then the manufacturing process is simple, but the manufacturing precision deteriorates as display surface dimensions increase
Solution Approach 1:
The light guide plate is divided into multiple layers: a plate body layer, an optical adhesive layer, and a light entrance structure layer. The light entrance structure layer with microstructures is separately manufactured and then bonded to the plate body, allowing precise control of microstructure formation independent of the overall plate size.
Solution Approach 2:
An optical adhesive layer is introduced as an intermediary between the plate body and the light entrance structure layer. This adhesive layer enables precise bonding while allowing the microstructures to be formed with high precision on the light entrance structure layer without being constrained by the overall plate dimensions.
2Productivity
If injection molding methods are used to form microstructures, then the manufacturing speed is fast, but the manufacturing precision deteriorates due to difficulty in controlling injection pressures
Solution Approach 1:
The manufacturing process is segmented into separate steps: first forming the plate body, then separately forming the light entrance structure layer with microstructures, and finally bonding them together. This allows the microstructures to be formed with high precision using suitable methods without compromising the overall manufacturing speed.
Solution Approach 2:
The manufacturing method changes from a single injection molding process to a multi-step process involving material distribution, curing, and bonding. This parameter change in the manufacturing approach enables precise control of microstructure formation while maintaining productivity through efficient process integration.
3Area of stationary object
If the light guide plate dimensions are increased to accommodate larger display surfaces, then the display capability is improved, but the manufacturing precision of microstructures deteriorates
Solution Approach 1:
The light guide plate is segmented into a plate body and a separate light entrance structure layer. This segmentation allows the microstructures to be formed with high precision on the lighter structure layer regardless of the overall plate size, while still accommodating large display surfaces through the plate body dimension.
Solution Approach 2:
The solution moves from a two-dimensional integral molding approach to a three-dimensional layered structure. The microstructures are formed on the light entrance structure layer which is positioned at a specific dimension (the light entrance side), allowing precise microstructure formation independent of the overall plate area.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances manufacturing efficiency and quality by ensuring seamless adhesion and reducing light convergence issues, maintaining high light transmittance and refractive index compatibility for improved brightness uniformity.
Implementation Method 1
The light-cured or thermal-cured structure is formed from light or thermal curable material that is cured by light or heat to form the light-cured or thermal-cured structure on the structured surface of the substrate
Implementation Method 2
The light-cured or thermal-cured structure is formed from light or thermal curable material that is cured by light or heat to form the light-cured or thermal-cured structure on the structured surface of the substrate
Implementation Method 3
An optical adhesive layer is attached onto the light entrance surface
Implementation Method 4
Light enters the plate body through the light entrance surface, propagates within the plate body by total internal reflection, and then exits the plate body from the light exit surface
Data Source
AI summary
A light guide plate and manufacture methods thereof are provided. The light guide plate includes a plate body, an optical adhesive layer, and a light entrance structure layer. The plate body has a light exit surface and a light entrance surface. The light entrance surface is connected to a side of the light exit surface and intersects the light exit surface with an angle. The optical adhesive layer is attached on the light entrance surface while the light entrance structure layer is attached to the optical adhesive layer. The light entrance structure layer includes a substrate and a light-cured or thermal-cured structure. The light-cured or thermal-cured structure is made of light or thermal curable material and firmly formed on a structured surface of the substrate through a light or thermal curing process.