Meandering Mold for Prism Sheet Brightness and Moiré Reduction
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Solution Overview
Problem
Conventional prism sheets manufactured using traditional molds are limited in their ability to refract light in two dimensions, leading to issues with brightness uniformity and the occurrence of moiré phenomena due to their constant patterns, making defect detection and optical film compatibility challenging.
Innovation Solution
A processing device utilizing piezoelectric elements to create molds with random or periodic meandering patterns, which are then used to manufacture prism sheets with varying heights and distances between crests and valleys, allowing for two-dimensional light refraction and reducing moiré effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional molds with flat surfaces are used, then the manufacturing process is simple, but the prism sheet can only refract light in one direction and brightness uniformity is poor
Solution Approach 1:
The patent applies curvature by forming meandering patterns (curved lines) on the mold surface using a processing device with oscillating cutting elements. The mold surface transitions from flat to curved with periodic undulations, enabling light to refract in multiple directions and improve brightness uniformity across the display panel
2Ease of manufacture
If conventional molds with constant patterns are used, then the manufacturing process is simple, but moiré phenomena occur due to regular repeating patterns
Solution Approach 1:
The patent introduces asymmetry by creating non-uniform meandering patterns where the amplitude, wavelength, or orientation of the curved lines varies across the mold surface. This asymmetric, non-repeating pattern prevents the formation of moiré effects while maintaining manufacturing simplicity through a single-step oscillating cutting process
3Adaptability or versatility
If molds with meandering patterns are used, then two-dimensional light refraction is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent uses periodic action by oscillating the cutting element at regular intervals during the molding process. This periodic oscillation automatically generates meandering patterns through the interaction of the oscillating cutter with the rotating or moving mold blank, achieving complex two-dimensional light refraction patterns without requiring complex multi-axis machining or multiple processing steps
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 resulting prism sheets exhibit enhanced brightness distribution and reduced moiré phenomena, with defects being difficult to visually detect, thus improving optical film compatibility and performance.
Implementation Method 1
at least one piezoelectric element (320a, 320b, 320c, and 320d)
Implementation Method 2
The prisms 210 make a light incident from the prism base 230 refract by passing it through the prisms 210
Data Source
AI summary
The present invention is directed to a mold. The present invention is also directed to a device for processing the same, and a replica made therefrom. A device for processing the mold comprises a cutting unit carving a surface of the mold; a housing accommodating the cutting unit and having an aperture through which a portion of the cutting unit protrudes; at least one piezo-electric element disposed between the cutting unit and the housing; and a signal generator applying an electrical signal to the piezoelectric element. The mold comprises a plurality of linear peaks and grooves that are formed on a surface of the mold, wherein both or one of the peaks and grooves have random or periodic meandering-shape. A replica manufactured by the mold comprises a plurality of linear crests and valleys that are formed on a surface of the replica, wherein both or one of the crests and valleys have random or periodic meandering-shape.