Optical Diffusion Film With Irregular Convexities
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Solution Overview
Problem
Conventional optical diffusion films in liquid crystal display units suffer from inadequate diffusion effects, leading to interference fringes, wet-out phenomena, and decreased display quality due to insufficient variation in lenticular heights, requiring labor-intensive and costly separate members and matte treatments.
Innovation Solution
An optical diffusion film with a convex structure on a resin film surface, featuring irregularly formed convexities without planar bottom portions, achieving wide-range diffusion and high transmission image sharpness, and fabricated using a roll forming process with spherical beads for improved gradient angles and reduced haze values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional optical diffusion films use structural members with regular lenticular heights, then manufacturing is simplified, but diffusion effect is inadequate causing interference fringes and wet-out phenomena
Solution Approach 1:
The patent applies asymmetry by replacing regular lenticular structures with irregular convexities of varying heights, widths, and spacing. This asymmetric design creates effective light diffusion while maintaining manufacturability through roll-forming processes, eliminating interference fringes and wet-out phenomena caused by regular periodic structures.
Solution Approach 2:
The patent changes multiple geometric parameters simultaneously - height, width, spacing, and curvature of convexities - to optimize diffusion performance. By varying these parameters irregularly rather than uniformly, the film achieves superior diffusion effect while controlling manufacturing complexity through standardized roll-forming techniques.
2Reliability
If conventional films use separate diffusion sheets and matte treatments, then diffusion effect is improved, but labor man-hours and costs increase
Solution Approach 1:
The patent merges the functions of diffusion sheets and matte treatments into a single integrated optical diffusion film. The irregular convexity structure on the film surface simultaneously provides light diffusion and matte appearance, eliminating the need for separate components and reducing assembly complexity while maintaining effective diffusion performance.
Solution Approach 2:
The optical diffusion film performs multiple functions simultaneously: it diffuses light, provides matte appearance, protects the display panel, and eliminates interference fringes. This multi-functional design replaces what previously required separate specialized components, reducing overall device complexity.
3Ease of manufacture
If conventional films have regular periodic structures, then manufacturing is easier, but display quality decreases due to moiré patterns
Solution Approach 1:
The patent eliminates regular periodic structures that cause moiré patterns by implementing irregular convexities with random variations in height, width, and spacing. This asymmetric design maintains manufacturing ease through roll-forming while significantly improving display quality by preventing moiré patterns and interference fringes.
Solution Approach 2:
The patent applies local quality variations through irregular convexities that differ in their geometric properties at different locations. This localized variation in structure creates effective diffusion and eliminates the regular periodicity that causes moiré patterns, while still allowing for consistent manufacturing processes.
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 film effectively diffuses light over a wide range, reducing glare and concealing minute flaws, while maintaining high display quality without the need for additional diffusion sheets or matte treatments, and achieving low reflectance and high transmission image sharpness.
Implementation Method 1
emitted light and incident light on a structured surface as well as reflected light thereof is diffused over a wide range within a viewing angle
Implementation Method 2
a convex structure in which a plurality of convexities of irregular heights and sizes are continuously formed at random
Data Source
AI summary
Measurement reference lengths of length and width are set with respect to a convex structure, and an average of vertical distances between tip points and bottom points inside a measurement reference area is calculated as an average height. An average of horizontal distances between the tip points and bottom points is calculated as an average distance. A value obtained by dividing the average height by the average distance provides a gradient ratio. An inverse tangent of the gradient ratio provides an average gradient angle. When the average gradient angle ranges from 5 degrees to 15 degrees and a standard deviation of average gradient angle ranges from 30% to 40% of the average gradient angle, a regular reflectance at a regular reflection angle with respect to incident light of an angle of 30 degrees from a normal direction of the film surface is 1% or less.