All-in-One Light Guide Plate Manufacturing with Integral Inverse-Prism Structures
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Solution Overview
Problem
Existing light guide type backlight apparatuses face challenges in achieving uniform light distribution and thinness due to the limitations of adhesive layers affecting light quality and the need for repeated master fabrication in forming inverse-prism shape structures.
Innovation Solution
A method for manufacturing an all-in-one type light guide plate by fabricating a master with inverse-prism shape structures, forming an elastic mold using an elastomer, and applying a light transmissive material to create a plate with integrally formed inverse-prism shapes, allowing for the production of multiple elastic molds from a single master.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inverse-prism shape structures are fixed on the light guide plate using an adhesive layer, then the light guide plate can be manufactured, but the adhesive layer interferes with and degrades the quality of light emission
Solution Approach 1:
The patent merges the inverse-prism shape structures directly into the light guide plate body through integral formation, eliminating the separate adhesive layer. This is achieved by forming the inverse-prism structures as part of the light guide plate manufacturing process itself, so that the light-emitting surface and the light-distributing structures become a single unified component without intervening adhesive layers that would degrade light quality.
Solution Approach 2:
The patent extracts and removes the adhesive layer from the system by integrating the inverse-prism structures directly into the light guide plate. By taking out the problematic adhesive component and replacing it with integral formation, the solution eliminates the source of light quality degradation while maintaining the light distribution function.
2Manufacturing precision
If a master is fabricated to form inverse-prism shape structures, then the light guide plate can be manufactured, but fabricating multiple masters is complex and time-consuming
Solution Approach 1:
The patent creates a universal master that can form multiple inverse-prism shape structures simultaneously. This single master is designed to create multiple light guide plates in one fabrication cycle, making it multi-functional. The master serves as a template that can be used repeatedly to produce many identical inverse-prism structures without requiring separate masters for each structure, thereby improving productivity while maintaining precision.
Solution Approach 2:
The patent segments the master into multiple functional zones that correspond to different inverse-prism structure positions. By dividing the master into multiple active areas, each capable of forming a complete inverse-prism structure, the system can produce multiple light guide plates simultaneously from a single master, reducing the need for repeated master fabrication and improving manufacturing efficiency.
3Illumination intensity
If multiple light sources are used to increase brightness, then the brightness is improved, but the backlight apparatus becomes thicker and power consumption increases
Solution Approach 1:
The patent applies local quality by creating non-uniform thickness in the light guide plate through the inverse-prism structures. The plate has varying thickness regions that optimize light distribution locally, allowing a single light source to achieve uniform brightness across the display area without requiring multiple light sources. This local optimization of light guiding efficiency eliminates the need for additional light sources that would increase thickness and power consumption.
Solution Approach 2:
The patent changes the physical parameters of the light guide plate by introducing variable thickness through inverse-prism structures. By modifying the thickness parameter locally at different positions, the system optimizes light extraction and distribution efficiency, enabling high brightness output from a single light source and avoiding the need for multiple light sources that would increase overall apparatus thickness.
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 approach enables efficient and rapid manufacturing of light guide plates with uniform inverse-prism structures, improving light distribution and reducing the complexity of master fabrication, while allowing for various light emitting structures and materials to be used.
Implementation Method 1
forming an elastic mold by applying an elastomer on the master
Implementation Method 2
applying a light transmissive material to create a plate with integrally formed inverse-prism shapes
Data Source
AI summary
Provided is a method of manufacturing an all-in-one type light guide plate. The method includes: fabricating a master including a plurality of inverse-prism shape structures; forming an elastic mold by applying an elastomer on the master; and fabricating the all-in-one type light guide plate, on which a plurality of inverse-prism shape structures are integrally formed, by applying a light transmissive material on the elastic mold.