Patterned Light Guide Structure with Protective Layer

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Solution Overview

Problem

The manufacturing process of light guides often results in particles adhering to the glass substrate, causing damage to the fragile photoresist layers, which deteriorates the quality and yield of the products.

Innovation Solution

A patterned light guide structure is developed with a robust protecting layer, comprising a transparent substrate, anti-reflective, first and second light-shielding layers, and a protecting layer, where the protecting layer is strategically positioned to prevent damage from particles and scratches, and a method involving a removable protecting layer is used to safeguard the light guide during fabrication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a cleaning procedure is used to remove particles from the glass substrate, then particle contamination is reduced, but the fragile black photoresist layer is damaged

Engineering Contradiction:

Improveparticle contaminationVSAvoidphotoresist layer integrity

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

A protecting layer is formed over the light-shielding layer before subsequent manufacturing steps. This preliminary protective measure prevents particles from adhering to the glass substrate and eliminates the need for cleaning procedures that would damage the photoresist layer.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protecting layer acts as an intermediary barrier between the external environment (particles) and the light-shielding layer. This intermediate layer allows the system to maintain cleanliness without direct contact between cleaning tools and the fragile photoresist, resolving the contradiction between particle removal and layer integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the light guide structure is made more robust to prevent damage, then durability is improved, but device complexity increases

Engineering Contradiction:

Improvelight guide durabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The light guide structure is segmented into multiple functional layers: a transparent substrate, a light-shielding layer with specific patterns, and a protecting layer. This segmentation allows each layer to perform its specific function while contributing to overall durability without requiring complete structural redesign.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite material structures where the protecting layer (with specific hardness properties) is combined with the light-shielding layer and transparent substrate. This composite approach enhances durability through material properties rather than increasing structural complexity.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11249245B2Patterned light guide structure and method to form the same

Publication Date: 2022.02.15 HIMAX TECH LTD

AI summary

A patterned light guide structure includes a transparent substrate with a first side and with a second side, an anti-reflective layer directly attached to the first side, a first light-shielding layer directly disposed on the anti-reflective layer, a second light-shielding layer directly disposed on the second side, and a protecting layer directly disposed on the first light-shielding layer to keep the first light-shielding layer from any deteriorating damage.