Microlens Diffuser Plate for Flat Light Distribution and Low Diffraction

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Solution Overview

Problem

Existing microlens array diffuser plates face a trade-off between reducing high-order diffraction components and maintaining flat diffusion angle distribution characteristics, as irregularly locating microlenses affects the angles of diffused light beams.

Innovation Solution

A microlens array diffuser plate with varying curvature radii and irregularly positioned lenses, where the lens surface shape satisfies specific equations, including a conic coefficient within a defined range, to achieve both reduced high-order diffraction and flat diffusion angle distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a light source is disposed close to the display panel to improve illumination efficiency, then illumination efficiency is improved, but uniformity of illumination deteriorates due to hot spots and glare

Engineering Contradiction:

Improveillumination efficiencyVSAvoiduniformity of illumination

Core Design Contradiction:

Use of energy by moving objectVSIllumination intensity

Solution Approach 1:

A diffuser plate is introduced as an intermediary component between the light source and the display panel. The diffuser plate receives light from the light source and redistributes it uniformly across the display panel area, eliminating hot spots and glare while maintaining high illumination efficiency. This mediator component resolves the contradiction by decoupling the light generation function from the light distribution function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The illumination system is segmented into distinct functional components: the light source module, the diffuser plate module, and the display panel module. The diffuser plate is positioned as a separate intermediary layer that independently handles light distribution, allowing the light source to be optimized for brightness while the diffuser plate ensures uniform illumination across the display area.

Inventive Principle:

Principle #1Segmentation

2Use of energy by moving object

If a light source is disposed close to the display panel to improve illumination efficiency, then illumination efficiency is improved, but quality of illumination deteriorates due to hot spots and glare

Engineering Contradiction:

Improveillumination efficiencyVSAvoidhot spots and glare

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The diffuser plate serves as a mediator that filters and redistributes light between the light source and the display panel. It eliminates harmful hot spots and glare by scattering light uniformly, while maintaining the high illumination efficiency achieved by placing the light source close to the display panel.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The diffuser plate converts the concentrated, potentially harmful light output from the close-proximity light source into a uniformly distributed beneficial illumination pattern. The light that would otherwise create hot spots and glare is transformed through the diffuser plate into even, comfortable lighting across the entire display area.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Device complexity

If conventional lighting structures are used to maintain simple structure, then device complexity is low, but illumination uniformity deteriorates

Engineering Contradiction:

Improvestructure simplicityVSAvoidillumination uniformity

Core Design Contradiction:

Device complexityVSIllumination intensity

Solution Approach 1:

The lighting structure is segmented into modular components (light source module, diffuser plate module) that can be independently manufactured and assembled. This segmentation maintains relative structural simplicity while achieving superior illumination uniformity through the specialized diffuser plate component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The diffuser plate utilizes light-scattering material properties to achieve uniform illumination. The plate's optical characteristics (scattering and diffusing properties) naturally distribute light evenly across the display panel without requiring complex mechanical structures or multiple light sources.

Inventive Principle:

Principle #31Porous materials

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 enables simultaneous reduction of high-order diffraction components and achievement of flat diffusion angle distribution characteristics, enhancing the diffuser plate's performance.

Implementation Method 1

a function of a light source and a diffuser plate, the light source being disposed close to the display panel and the diffuser plate being disposed between the light source and the display panel

Methodology Applied

Scientific EffectLight scattering: Scattering

Data Source

PatentEP3309592B1Diffuser plate, display device, projection device, and illumination device

Publication Date: 2026.05.20 DEXERIALS CORP

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AI summary

[Object] To provide a diffuser plate, a display device, a projection device, and a lighting device that can achieve flat diffusion angle distribution characteristics, while reducing a high-order diffraction component. [Solution] A diffuser plate according to the present invention includes a single lens group positioned on a surface of a transparent substrate, in which curvature radii of respective single lenses composing the single lens group are varied as a whole, and peak positions of the respective single lenses are located irregularly, and a lens surface shape of at least one of the single lenses in the single lens group satisfies Equation 1 and Equation 2.