Low Refractive Index Light Extraction Member for Cost Reduction
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Solution Overview
Problem
Conventional light extraction members require complex designs and structures, are difficult to composite with other members, have low productivity, and are expensive, making them inefficient and costly.
Innovation Solution
A light extraction member with a light guide portion and a light output control layer having a refractive index difference, where the light output control layer is patterned and coated with a pressure-sensitive adhesive layer, allowing for continuous formation and easy integration with other members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional light extraction member uses a complicated uneven shape to achieve desired light extraction pattern, then light extraction performance is improved, but device complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent changes the refractive index parameter of the light guide portion to be lower than conventional values (using materials with refractive index 1.35-1.65 such as cyclic polyolefin or polycarbonate), which fundamentally alters the light extraction mechanism. This parameter change enables the use of simple flat or slightly uneven surfaces instead of complicated uneven shapes, thereby maintaining light extraction performance while reducing structural complexity
Solution Approach 2:
Instead of creating complicated surface unevenness to extract light, the patent inverts the approach by using a low refractive index material that naturally enables light extraction through its optical properties. The light extraction function is achieved through material property inversion rather than geometric complexity
2Reliability
If a conventional light extraction member uses a complicated uneven shape and periodic patterns, then light extraction pattern is controlled, but productivity decreases and manufacturing cost increases
Solution Approach 1:
By changing the refractive index parameter to lower values, the patent eliminates the need for periodic pattern formation and complex surface shaping. The light extraction pattern is controlled through the inherent optical properties of the low refractive index material, enabling continuous sheet production without repeated patterning processes, thus significantly improving productivity
Solution Approach 2:
The low refractive index material serves multiple functions simultaneously: it provides light extraction, controls light extraction patterns, and enables continuous manufacturing. This multi-functionality eliminates the need for separate periodic pattern structures, simplifying the overall design and improving manufacturing efficiency
3Reliability
If a conventional light extraction member uses complex design and structure, then desired light output characteristic is achieved, but ease of manufacture and composability with other members deteriorate
Solution Approach 1:
The patent uses low refractive index materials (cyclic polyolefin with n=1.45-1.55 or polycarbonate with n=1.58-1.62) that inherently provide desired light output characteristics through their optical properties. This eliminates the need for complex surface structuring, resulting in flat or slightly uneven surfaces that are easy to manufacture and composite with other members using conventional techniques
Solution Approach 2:
The patent employs homogeneous low refractive index materials throughout the light guide portion, eliminating the need for heterogeneous complex surface structures. This homogeneity simplifies manufacturing processes and enhances composability with other members, as uniform surfaces are easier to bond and integrate
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
The solution provides a desired light output characteristic without complex designs, enhances productivity, and reduces costs by enabling easy composition with other members and handling, while maintaining efficient light extraction.
Implementation Method 1
A refractive index n1 of the light guide portion and a refractive index n2 of the light output control layer satisfy a relationship of n1>n2
Data Source
AI summary
Provided is a light extraction member which can be obtained at an adequate cost, while achieving desired light output characteristics without requiring complicated design and structure, and which is easily combined with another member, while exhibiting excellent productivity and excellent handling properties. A light extraction member according to the present embodiment includes: a light guide part which has a first main surface being on the light output side and a second main surface being on the reverse side of the first main surface; and a light output control layer which is a predetermined pattern formed on the first main surface. With respect to this light extraction member, the refractive index n1 of the light guide part and the refractive index n2 of the light output control layer satisfy relational expression n1>n2; and the refractive index n2 of the light output control layer is from 1.01 to 1.30.