3D Complex Multilayer Optical Sheet for Display Luminance
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Solution Overview
Problem
Conventional optical sheets used in displays, such as liquid crystal displays, require multiple layers to achieve desired luminance and contrast, leading to increased cost and complexity, and existing methods for manufacturing complex 3D multilayer structures are cumbersome and limit the size and complexity of patterns that can be formed.
Innovation Solution
A 3D complex multilayer structure with distinct patterns on both surfaces, including parallel lines, curves, and zigzag lines, formed using a heat- or active energy ray-curable resin, where the patterns are orthogonal to each other and create figures like polygons and ellipses, allowing for simplified manufacturing and reduced layer count, enabling the structure to perform functions of multiple optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple optical sheets are stacked to achieve desired luminance and contrast, then display quality is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple optical sheet functions (diffusion, prism, protection) into a single integrated optical sheet with a multilayer structure. The first pattern layer provides diffusion function, the second pattern layer provides prism function, and they are integrated in one sheet rather than stacked separately, thereby reducing the number of layers while maintaining luminance and contrast performance
Solution Approach 2:
The single optical sheet is designed to perform multiple functions simultaneously: the first pattern layer diffuses light, the second pattern layer focuses light through prism effects, and the structure provides protection. This multi-functional integration replaces what previously required multiple separate optical sheets, reducing device complexity while achieving the desired illumination intensity
2Manufacturing precision
If conventional methods are used to manufacture complex 3D multilayer structures, then manufacturing capability is maintained, but ease of manufacture and productivity decrease
Solution Approach 1:
The manufacturing process is segmented into two independent stages: first forming the first pattern layer with its specific pattern, then forming the second pattern layer with its different pattern on the same sheet. This segmentation allows each layer to be manufactured using optimized processes without interfering with the other, simplifying the overall manufacturing while achieving complex 3D multilayer structures
Solution Approach 2:
The patent transitions from planar 2D patterns to 3D multilayer patterns by adding vertical dimensionality. The first and second pattern layers are formed at different heights/thicknesses on the optical sheet, creating a 3D complex structure that enables multiple optical functions in a single component, thereby improving manufacturing efficiency and pattern complexity simultaneously
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 3D complex multilayer structure achieves improved luminance and reduced optical loss by combining functions of multiple optical sheets in a single layer, simplifying production and enhancing economic efficiency, while allowing for larger pattern sizes and more complex designs.
Implementation Method 1
a heat- or active energy ray-curable resin
Data Source
AI summary
The present invention relates to a 3-dimensional complex multilayer structure. The 3-dimensional complex multilayer structure includes a first pattern and a second pattern having different thicknesses formed on one or both surfaces of a plate. The first pattern is selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other. The second pattern is not parallel to the first pattern and is selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other. The interfaces between the first pattern and the second pattern form figures selected from the group consisting of polygons, circles, ellipses, and combinations thereof. The figures are repetitively formed on one or both surfaces of the plate. The 3-dimensional complex multilayer structure includes different complex patterns, whereas a conventional device has a kind of simple pattern. The 3-dimensional complex multilayer structure of the present invention can be manufactured by a simple process. Therefore, the 3-dimensional complex multilayer structure of the present invention can find application in various fields, including optical components for displays (e.g., light guide plates, diffusion plates, prisms, and color filters), next generation displays and display devices (e.g., TFTs, OTFTs, oxide TFTs, flexible displays, and transparent displays), next generation 3-dimensional semiconductors, dry adhesion based on the use of fine ciliary structures, micro/nano piezoelectric devices, lighting optical components, and biocell/virus research using micropatterns.