Optical Body Surface Structure for Light Extraction and Anti-Reflection
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Solution Overview
Problem
Existing methods for manufacturing optical bodies with both macro and micro concave-convex structures require separate steps and high precision, leading to increased effort and poor productivity, especially when high precision or yield is demanded.
Innovation Solution
A method involving a base material with a first optical layer having a random or specific concave-convex structure for light extraction and a second optical layer with a periodic concave-convex structure for reducing reflections, using a nanoimprint process with a concave-convex structure master to form these structures efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate steps are used to form macro and micro concave-convex structures on the master, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent combines the formation of macro concave-convex structures and micro concave-convex structures into a single stamping step using a unified master. The master includes both macro convex portions (for light emission regions) and micro convex portions (for anti-reflection regions) on its surface, allowing both types of structures to be formed simultaneously on the optical body without requiring separate manufacturing steps.
Solution Approach 2:
The master is segmented into different functional regions: macro convex portions corresponding to light emission regions and micro convex portions corresponding to anti-reflection regions. This segmentation allows each region to perform its specific function while being formed in a single stamping operation, resolving the contradiction between precision and productivity.
2Manufacturing precision
If high precision is demanded for positioning the light-emitting region, then manufacturing precision is improved, but effort and time increase
Solution Approach 1:
The positioning of light-emitting regions and the formation of anti-reflection structures are merged into a single stamping operation. The master's surface structure inherently defines both the light-emission patterns and the anti-reflection regions, eliminating the need for separate positioning and manufacturing steps that would consume additional time.
3Manufacturing precision
If a master is manufactured for every shape of light-emitting region, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The master is designed with universal applicability through its dual-function surface structure that combines both macro and micro convex portions. This unified master can produce optical bodies with different light-emitting region shapes by varying the stamping parameters or master configurations, eliminating the need to manufacture a completely new master for each design variation and thereby 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
Enhances light extraction efficiency and reduces extraneous light reflections, improving productivity and enabling high-precision, cost-effective manufacturing of optical bodies with enhanced design capabilities.
Implementation Method 1
a first optical layer 11 formed on a partial region on one of the surfaces 10A, 10B of the base material 10. The first optical layer 11 includes a first concave-convex structure 11c. The first concave-convex structure 11c extracts and emits the internally propagating light to the outside
Implementation Method 2
Light incident inside the light guide panel, or in other words, internally propagating light, propagates inside the light guide panel while reflecting off the surface of the light guide panel
Implementation Method 3
a second optical layer 12 formed on the other surface 10B of the base material 10. The second optical layer 12 reduces reflections of extraneous light
Implementation Method 4
a micro concave-convex structure for reducing reflections of extraneous light is often formed
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
An aspect of the invention relates to an optical body (1) comprising: a base material (10) configured to propagate light incident inside the base material (10) from a side face of the base material (10); a second optical layer (12), formed on at least one surface of the base material (10), configured to reduce a reflection of extraneous light at the surface of the base material (10), wherein the second optical layer (12) includes a second concave-convex (12c) in which an average cycle of concavities and convexities is lower than a visible light wavelength band; and a first optical layer (11), laminated on top of a part of the second optical layer (12), configured to extract internally propagating light incident inside the base material (10) to an outside of the base material (10), wherein on a surface of the first optical layer (11), a first concave-convex structure (11c) configured to reflect the internally propagating light is formed, wherein the first concave-convex structure (11c) includes a number of first convexities (11a) and first concavities (11b), wherein the first convexities (11a) have a shape protruding outward in a thickness direction of the optical body (1), while the first concavities (11b) have a shape depressed inward in the thickness direction of the optical body (1). Further aspects relate to a method for manufacturing an optical body and a light-emitting apparatus.