Multilayer Optical Panel Co-Extrusion for Brightness and Concealing
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Solution Overview
Problem
Conventional optical function panels face challenges in balancing light transmission and concealing properties, often sacrificing one property for the enhancement of the other, which limits their application in backlight modules.
Innovation Solution
A multilayer optical function panel is developed, comprising a thicker main layer made of transparent materials like PMMA, PS, or PC, combined with a thinner functional layer featuring regular or irregular salient structures and made of different materials, which are co-extruded and bonded with an optical film layer using a UV adhesive, allowing for adjustable thickness and improved light scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If formulae or additives are used to enhance concealing property, then haze property is improved, but transmittance property deteriorates
Solution Approach 1:
The patent divides the optical function panel into multiple independent layers: a main layer for light transmission and a functional layer for concealing property. This segmentation allows each layer to optimize its specific function without compromising the other, resolving the contradiction between transmittance and concealing properties.
Solution Approach 2:
The patent uses composite material structure combining different materials with complementary properties in separate layers. The main layer uses transparent materials (PMMA, PS, PC) for high transmittance, while the functional layer uses materials with particles for enhanced concealing property, achieving both requirements simultaneously.
2Object-affected harmful factors
If light beam angle is increased to 160°-176°, then diffusion effect is improved, but illuminance decreases
Solution Approach 1:
The patent segments the light diffusion function across multiple layers with different functions. The main layer maintains high transmittance and controlled light path, while the functional layer with particles provides the diffusion effect. This allows optimization of both illuminance and diffusion performance.
Solution Approach 2:
The patent applies different optical properties to different layers locally. The main layer has high transmittance and uniform optical properties, while the functional layer has particle distributions that create localized diffusion effects. This local differentiation enables simultaneous optimization of illuminance and diffusion.
3Object-affected harmful factors
If surface is treated by dull polish or embossing, then concealing property is improved, but transmittance property deteriorates
Solution Approach 1:
The patent separates the concealing function into a dedicated functional layer with particles, eliminating the need for surface treatments like dull polish or embossing on the main layer. This segmentation preserves the transmittance property of the main layer while achieving concealing effect through the functional layer's particle distribution.
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 design enhances brightness and concealing properties independently of additives, reducing the thickness and cost of backlight modules while maintaining optimal transmittance and haze properties, making it suitable for various lighting products.
Implementation Method 1
the functional layer is provided with two layers respectively disposed on the upper surface and the lower surface of the main body layer... one or some of such formulae or functional additives as diffusant/particles... are combined by physical or chemical means, molten to form a thin layer by in-mold extrusion
Implementation Method 2
the upper surface of the main body is bonded to an optical film layer through a UV adhesive layer
Data Source
AI summary
An optical function panel having a main body comprises a main layer and at least a functional layer combined with main layer, wherein the main layer is thicker than functional layer, and the main layer is composed of a transparent material, the main layer and functional layer are formed by co-extrusion in an extruder, and are formed with regular or irregular salient structures on an upper or/and a lower surface of the main body. The thicknesses of main layer and functional layer and formulae or additives can be adjusted flexibly. The brightness can be increased by the serrated structures on the upper surface of main body while the concealing property is invariant; and the main layer and functional layer are independent of the absolute influence of formulae or additives on the transmittance property of diffuser plate.