Monolithic Wedge Light Guide With Integrally-Formed Optical Concentrators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The precision and optical quality of wedge light guides are compromised due to the separate construction and mounting of optical concentrators, which can lead to registration issues and light loss.
Innovation Solution
The integration of optical concentrators directly into the mold for forming a monolithic wedge light guide, allowing for simultaneous formation with the wedge structure and eliminating secondary parts, thereby improving optical quality and reducing light loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical concentrators are separately constructed and mounted on the wedge light guide, then the manufacturing process is simplified in terms of tooling, but registration precision and optical quality deteriorate due to alignment issues and light loss at interfaces
Solution Approach 1:
The patent merges the optical concentrators with the wedge light guide by forming both as a single monolithic structure through co-injection molding. This integration eliminates the separate mounting step that causes registration issues, while the multi-cavity mold design maintains manufacturing efficiency by producing both components simultaneously in one process cycle.
2Device complexity
If optical concentrators are separately mounted on the wedge light guide, then device assembly is simpler with modular components, but optical quality and light guidance efficiency worsen due to interface light loss and registration problems
Solution Approach 1:
The optical concentrators and wedge light guide are merged into a single monolithic component with no interfaces between them. This eliminates light loss at mounting interfaces and ensures perfect registration, significantly improving optical quality and light guidance efficiency while maintaining ease of manufacture through co-injection molding.
3Adaptability or versatility
If optical concentrators are physically affixed to the constructed wedge light guide, then manufacturing flexibility is maintained, but production time and productivity worsen due to additional assembly steps
Solution Approach 1:
The mold is designed with pre-defined optical concentrator structures and injection ports before the molding process begins. The formation material is injected directly into these pre-configured cavities, forming both the wedge light guide and optical concentrators in a single simultaneous operation, eliminating post-construction assembly steps and significantly improving productivity.
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
This approach results in a uniform, continuous wedge light guide with improved optical quality and reduced registration problems, enhancing the precision and efficiency of light guidance.
Implementation Method 1
Light guides are wave guides configured to guide visible light between two interfaces via total internal reflection
Implementation Method 2
The wedge light guide and its associated optical concentrators are defined by a mold. In at least some embodiments, structure within the mold that defines the optical concentrators can be used as injection ports through which formation material can be injected to form the monolithic wedge light guide
Data Source
AI summary
In one or more embodiments, wedge light guides are constructed that are monolithic in nature and include integrally-formed optical concentrators. The wedge light guide and its associated optical concentrators are defined by a mold. In at least some embodiments, structure within the mold that defines the optical concentrators can be used as injection ports through which formation material can be injected to form the monolithic wedge light guide.