Microstructure Diffuser for Uniform Light Beam Generation
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Solution Overview
Problem
Existing diffusers face challenges in achieving uniform light beams due to low yield rates and reliability issues, primarily because they often have single optical effects and pointed tips that complicate manufacturing and assembly, leading to reduced performance when combined with other optical lenses.
Innovation Solution
A microstructure diffuser with a light-entering and light-emitting portion featuring multiple microstructure units, including trapezoid-shaped and curved structures, which combine light splitting and diffusion effects to produce a uniform light beam, while avoiding pointed tips that could damage other optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single prism structure is used on the light-emitting surface, then the manufacturing process is simplified, but the uniformity of light beam is poor
Solution Approach 1:
The patent combines multiple optical structures (prism structures and lens structures) on the same light-emitting surface to achieve both beam splitting and beam diffusing effects simultaneously, resolving the contradiction between manufacturing simplicity and light beam uniformity
Solution Approach 2:
The optical structure is designed to perform multiple functions: the prism structures provide beam splitting while the lens structures provide beam diffusing, allowing a single component to achieve comprehensive light uniformity improvement
2Reliability
If a prism with pointed tip is used, then the beam-splitting effect is achieved, but the optical film may be scratched so that the reliability is reduced
Solution Approach 1:
The patent replaces the pointed tip of the prism with a curved or rounded surface, eliminating the sharp edge that could scratch the optical film while maintaining the beam-splitting optical effect through controlled curvature
3Productivity
If a prism with pointed tip is used, then the beam-splitting effect is achieved, but the yield rate of the diffuser is reduced
Solution Approach 1:
The patent integrates multiple optical functions into a unified structure where prism structures and lens structures work together on the same surface, improving yield rate by eliminating the need for separate components while managing structural complexity through systematic design
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 microstructure diffuser achieves highly uniform light beams by integrating both light splitting and diffusion effects, improving yield rates and reducing manufacturing complexities, and minimizing damage to other optical components, thus enhancing the reliability and efficiency of backlight modules.
Implementation Method 1
the first side surface and the second side surface of the first microstructure unit receive the light beam of the light source to form a first optical path
Implementation Method 2
The top surface of the first microstructure unit receives the light beam of the light source to form a second optical path
Implementation Method 3
The second microstructure unit receives the light beam of the light source to form a third optical path
Data Source
AI summary
A microstructure diffuser includes a light-entering surface, a light-emitting surface, and a plurality of microstructure portions having a first microstructure unit and a second microstructure unit. The first microstructure unit includes a first side surface, a second side surface, a top surface, a first pitch (P1), a second pitch (P2), and a height (H). The second microstructure unit has a curve function shape and is located at the light-emitting surface. The first side surface and the second side surface of the first microstructure unit receive the light beam of the light source to form a first optical path. The top surface of the first microstructure unit receives the light beam of the light source to form a second optical path. The second microstructure unit receives the light beam of the light source to form a third optical path.