Optical Film Micro-Structures for Thin Display Brightness Uniformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional injection and extrusion molding processes for manufacturing light guiding panels are limited in producing panels narrower than 0.3 mm, leading to difficulties in achieving thin panels and often result in mura or hotspot issues that affect display quality.
Innovation Solution
The use of a laser cutting process to form micro-structures on an optical film, including bubble structures on the first surface and protrusions and recesses on the second surface, which addresses brightness uniformity and hotspot issues by altering the light path and reducing roughness without the need for polishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If injection and extrusion molding processes are used to manufacture light guiding panels, then the manufacturing process is simple, but the width of the light guiding panel is limited and cannot be less than 0.3 mm
Solution Approach 1:
The patent replaces the conventional injection and extrusion molding processes with a laser cutting process to manufacture the optical film. This substitution enables the production of light guiding panels with widths less than 0.3 mm while avoiding the dimensional limitations of mechanical molding processes.
2Length of stationary object
If panels are made thinner to improve display device thickness, then the device becomes thinner, but mura or hotspot issues occur affecting display quality
Solution Approach 1:
The patent introduces micro-structures (protrusions and recesses) at specific locations on the light guiding panel to locally modify light distribution. These micro-structures are strategically positioned to address brightness uniformity issues and eliminate mura or hotspot effects in thin panels.
Solution Approach 2:
The patent adds a micro-structural dimension to the otherwise flat light guiding panel surface. By creating protrusions and recesses that extend beyond the main surface plane, the design controls light paths in three dimensions to achieve uniform brightness distribution.
3Ease of manufacture
If conventional molding processes are used, then manufacturing is easier, but the optical film deforms during manufacturing
Solution Approach 1:
The patent replaces mechanical molding processes with laser cutting, which uses optical energy instead of mechanical force. This substitution eliminates the deformation issues associated with mechanical molding while maintaining manufacturing efficiency.
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 solution effectively maintains a thin display device with improved brightness uniformity, reducing hotspot and mura issues, and allows for the production of narrower light guiding panels without deforming the optical film during manufacturing.
Implementation Method 1
Micro-structures are formed on the optical film by laser cutting process
Implementation Method 2
laser cutting process to form micro-structures on an optical film
Implementation Method 3
altering the light path
Implementation Method 4
first micro-structure includes a plurality of bubble structures, the second micro-structure includes a plurality of protrusions and recesses
Data Source
AI summary
An optical film having a first surface and a second surface is provided. The second surface is adjacent to the first surface and has a first area connected to the first surface, a second area connected to the first area, and a third area connected to the second area. The optical film includes a first micro-structure disposed on the first surface and a second micro-structure disposed in the first area and the second area. The first micro-structure includes a plurality of bubble structures. The second micro-structure includes a plurality of protrusions and recesses.