Optical Diffusion Structure with Curved Micro-Lens Arrays
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Solution Overview
Problem
Conventional optical diffusion structures, such as micro-lens arrays, face challenges in uniformly diffusing light from point or linear light sources due to high manufacturing complexity and limited control over diffusion directions, while blurred and grained structures suffer from intensity reduction and restricted diffusion angles.
Innovation Solution
A two-dimensional optical diffusion structure comprising alternating arrays of convex and concave portions formed using a laser dragging method, where the convex and concave portions have non-zero curvature, allowing for controlled light diffusion in multiple dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a blurred structure or grained structure is used for diffusion, then the structure is simple and manufacturing is easy, but light intensity is reduced and diffusion angle is limited
Solution Approach 1:
The patent employs a micro-lens array with curved surfaces (convex and concave portions) to achieve effective light diffusion. The curved geometry of the lenses allows for better light control and higher intensity compared to flat blurred or grained structures, while still maintaining manufacturing feasibility through established lens fabrication techniques.
Solution Approach 2:
The diffusion structure is divided into multiple discrete micro-lenses arranged in an array, rather than using a continuous blurred or grained structure. This segmentation allows each lens to independently control light diffusion in specific directions while maintaining overall manufacturing simplicity through repetitive patterning processes.
2Illumination intensity
If a micro-lens array is used to control diffusion direction, then light intensity is maintained and diffusion direction is controllable, but manufacturing complexity increases
Solution Approach 1:
The diffusion function is divided into multiple discrete micro-lenses that can be independently designed and manufactured. This segmentation allows for precise control of light diffusion directions through the arrangement and geometry of individual lenses, while simplifying manufacturing by using repetitive patterning techniques rather than complex continuous structures.
Solution Approach 2:
Different regions of the micro-lens array have different lens geometries (convex and concave portions) to control light diffusion in specific directions. This local variation in quality allows for precise directional control of light while maintaining a relatively simple overall manufacturing process through standardized lens fabrication methods.
3Manufacturing precision
If laser dragging method is used to form micro-lens array, then manufacturing precision can be controlled, but the process becomes complex with multiple parameters to optimize
Solution Approach 1:
The patent optimizes key parameters of the laser dragging process (laser power, dragging speed, number of repeated operations) to achieve the desired micro-lens array profile. By systematically controlling these parameters, the process achieves high manufacturing precision for lens curvature and depth while managing complexity through established process guidelines.
Solution Approach 2:
The mask pattern is designed in advance with specific opening sizes and shapes to pre-determine the micro-lens array geometry. This preliminary design allows for precise control of lens dimensions and curvature before the actual laser dragging process, simplifying the overall manufacturing process by establishing clear target specifications.
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 structure effectively enhances light diffusion uniformity and intensity by allowing precise control over diffusion directions, improving the performance of backlight modules with LED arrays.
Implementation Method 1
A laser beam B passes through a mask 5 and reaches a substrate 10. When the mask 5 moves in a direction L7, the laser beam etches the substrate 10 to form grooves 12 which constitute a micro-lens array.
Implementation Method 2
The convex portions, the concave portions and each junction of the convex and concave portions have a curvature other than 0
Data Source
AI summary
An optical diffusion structure includes an optical diffusion structure comprising a plurality of convex portions and a plurality of concave portions. Each convex portion is adjacent to a plurality of concave portions and each concave portion is adjacent to a plurality of convex portions. The convex portions, the concave portions and each junction of the convex and concave portions have a curvature different from 0. The optical diffusion structure further includes a diffusion plate having a first surface, wherein the optical diffusion structure is formed on the first surface, and the convex portions are arranged in a two dimensional array along a first direction and a second direction, and the concave portions are arranged in a two dimensional array along a third direction and a fourth direction.