Optical Element Integrating Diffusion and Collimation Patterns
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Solution Overview
Problem
Conventional backlight modules for electronic devices suffer from low luminous efficacy and high manufacturing costs due to the use of multiple optical films, with existing solutions requiring complex processes and high skill levels for mass production.
Innovation Solution
An optical element with integrated microstructures, featuring a combination of semi-lenticular lenses for diffusion and prisms for collimation, formed on a substrate using a roller embossing process, which simplifies manufacturing and enhances light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate diffusion layer and collimation layer are used, then light diffusion and collimation functions are achieved, but manufacturing cost increases and luminous efficacy decreases
Solution Approach 1:
The patent combines the diffusion layer and collimation layer into a single integrated optical element. The optical element includes a substrate with a diffusion pattern on its first surface and a collimation pattern on its second surface, eliminating the need for separate diffusion and collimation components. This merging reduces the number of manufacturing steps and assembly operations while maintaining both light diffusion and collimation functions, thereby reducing manufacturing cost and improving luminous efficacy by eliminating light loss at multiple interfaces.
2Illumination intensity
If multiple optical films are used in conventional backlight, then illumination uniformity is improved, but manufacturing complexity and assembly yield decrease
Solution Approach 1:
The patent integrates multiple optical functions into a single optical element that includes both diffusion and collimation patterns on opposite surfaces of a substrate. This consolidation replaces multiple separate optical films in conventional backlight designs, reducing manufacturing complexity and improving assembly yield while maintaining illumination uniformity across the display surface.
Solution Approach 2:
The optical element divides light manipulation into two distinct functional surfaces: the first surface with diffusion patterns for scattering light to achieve uniform illumination, and the second surface with collimation patterns for directing light in specific directions. This segmentation of functions within a single integrated component allows each surface to be optimized independently while simplifying the overall system architecture.
3Productivity
If diffusion and collimation are performed in separate processes, then optical functions are achieved, but production time and cost increase
Solution Approach 1:
The patent combines diffusion and collimation patterns into a single optical element that can be manufactured in one integrated process. The substrate is formed with both the diffusion pattern on the first surface and the collimation pattern on the second surface simultaneously or in sequence as part of a single manufacturing workflow, eliminating the need for separate diffusion and collimation fabrication processes and reducing production time and cost.
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 optical element improves luminous efficacy and reduces manufacturing costs by simultaneously diffusing and collimating light, offering a more efficient and cost-effective alternative to traditional brightness enhancement films and diffusers.
Implementation Method 1
at least a transparent diffusion unit, for diffusing the incident light
Implementation Method 2
at least a transparent collimation unit, for collimating the incident light
Data Source
AI summary
The present invention discloses an optical element, having a first optical surface and a second optical surface for receiving an incident light, the optical element comprising: at least a transparent diffusion unit, for scattering the incident light, each being placed on the first optical surface; and at least a transparent collimation unit, for collimating the incident light, each being place on the first optical surface abutted and adjacent to the diffusion unit in an alternative manner.