Multilayer Light Guide Plate Co-Extrusion for Display Reflection
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Solution Overview
Problem
Existing front light modules for display devices with light guide plates (LGP) often suffer from reduced manufacturing yield due to impurities attaching between the LGP and the optical clear adhesive (OCA) during the jacketing process, which also causes discomfort from reflection beams.
Innovation Solution
A multilayer LGP structure formed by co-extrusion of different polymer materials, such as polycarbonate and polymethyl methacrylate, with the second layer undergoing anti-glare or hard coating treatments, eliminating the need for an additional protection film and OCA, thereby enhancing yield and reducing reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an outer protection component (protection film) is added to protect the LGP from scratches, then the LGP surface protection is improved, but reflection beams are generated that discomfort the user
Solution Approach 1:
The patent merges the protection film and OCA into a single integrated multilayer LGP structure. The OCA layer is directly formed on the protection film during the extrusion process, eliminating the need for separate jacketing. This integration maintains surface protection while the OCA's optical properties reduce harmful reflections.
Solution Approach 2:
The patent uses composite materials by combining different polymer materials with distinct optical properties in the multilayer LGP structure. The protection film provides mechanical protection while the OCA layer with specific refractive index reduces reflection beams, achieving both protection and optical performance through material composition.
2Ease of manufacture
If OCA is coated and adhered to the protection film in bulk roll manner and cut into sheet materials, then the LGP jacketing is completed, but impurities are attached between the LGP and OCA which lowers manufacturing yield
Solution Approach 1:
The patent applies preliminary action by forming the OCA layer directly on the protection film during the extrusion process before the LGP assembly is completed. This pre-forming of the OCA layer eliminates subsequent jacketing steps and prevents impurity attachment that would occur during separate OCA application and cutting operations.
Solution Approach 2:
The patent merges the OCA coating process with the LGP extrusion process into a single integrated operation. The OCA layer is extruded directly onto the protection film in bulk roll form, eliminating the need for separate cutting and adhering steps, thus preventing impurity attachment and improving manufacturing yield.
3Reliability
If multiple separate components (protection film, OCA, LGP) are used, then surface protection and light transmission are achieved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges multiple separate components (protection film, OCA, and LGP structure) into a single integrated multilayer LGP assembly. The OCA layer is directly formed on the protection film during extrusion, reducing the number of discrete components and simplifying the manufacturing process while maintaining all necessary functions.
Solution Approach 2:
The multilayer LGP structure serves multiple functions simultaneously: the protection film provides mechanical protection, the OCA layer reduces reflection and enhances light transmission, and the integrated structure eliminates the need for separate jacketing processes. This multi-functionality reduces device complexity while maintaining reliability.
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 multilayer LGP structure improves manufacturing yield and display quality by preventing impurity attachment and minimizing reflection, while maintaining surface protection and efficient light transmission.
Implementation Method 1
The first LGP layer and the second LGP layer are formed by performing a co-extrusion process
Implementation Method 2
the second LGP layer undergoes anti-glare or hard coating treatments, eliminating the need for an additional protection film and OCA, thereby enhancing yield and reducing reflection
Data Source
AI summary
A display device that includes a display panel, a multilayer light guide plate structure, and a light source is provided. The display panel has a display surface. The multilayer light guide plate structure is located on the display surface of the display panel. The multilayer light guide plate structure has a light incident surface, an upper surface, and a lower surface opposite to the upper surface, and the multilayer light guide plate structure includes a plurality of light guide plate layers stacked together. The light source is located beside the light incident surface of the multilayer light guide plate structure and has a light emitting surface. A multilayer light guide plate structure and a front light module are also provided.