Optical Film Microstructure Angle for Glare Control
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Solution Overview
Problem
Existing optical films with random base angles for microstructures fail to effectively control glare and achieve optimized light distribution curves, especially with non-directional light sources like OLEDs, leading to inefficient shaping of emitted light.
Innovation Solution
An optical film with a microstructure featuring elevations that have a uniform angle between 33° to 42°, allowing for efficient glare reduction and precise light shaping, made from light-transmitting materials like polycarbonate, which can be easily manufactured and adapted for various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If films with random base angles for microstructures are used, then the light source becomes less visible and some light diffusion is achieved, but satisfactory glare control is not achieved and the light distribution curve cannot be optimized
Solution Approach 1:
The patent changes the parameter of the microstructure base angle from random (10°-60°) to a specific uniform range (33°-42° or 35°-40°). This parameter change enables both effective glare control and optimized light distribution curves while maintaining ease of manufacture through consistent angular specifications that can be achieved through standard molding processes.
2Reliability
If structures are ground into a solid substrate to create optics, then the optics can be shaped and light can be modified, but the manufacturing becomes expensive and difficult especially for large luminaires
Solution Approach 1:
The patent uses a thin film with microstructures instead of modifying a solid substrate. The film can be manufactured separately with precise microstructures through molding, then applied to the luminaire surface. This approach maintains reliable optical performance for light shaping and diffusion while dramatically reducing manufacturing complexity and cost, especially for large luminaires.
3Object-affected harmful factors
If a uniform angle range of 33° to 42° or 35° to 40° is used for protrusion flanks, then glare control and light distribution are optimized, but the microstructure design becomes more specific
Solution Approach 1:
The patent defines a specific parameter range for the uniform angle (33°-42° or 35°-40°) that optimizes glare control and light distribution. While this creates a more specific design requirement, the range is wide enough to allow manufacturing flexibility and does not significantly increase design complexity compared to the previous random angle approach.
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 achieves high glare control and precise light distribution, minimizing undesirable effects like rainbow effects and enabling compact, aesthetically pleasing lighting solutions for diverse applications.
Implementation Method 1
The protrusions of the microstructure are designed as cones, prisms, or pyramids... intended to have a random value between 10° and 60°. The microstructure is intended to help the optics fitted with the film to diffuse penetrating light by directing the light away from the sides of the microstructure's protrusions.
Implementation Method 2
such a luminaire comprises a housing, a light source in the housing, and an optical film in the housing... the optical film covers the light source in one emission direction from the luminaire
Data Source
Figure 1~2
Figure 3~4
AI summary
An optical film (1) made of a light-permeable material comprises a surface (13) and an optical micro-structure (11) having a plurality of elevations (111). The elevations (111) in the micro-structure (11) project from a reference plane (15) that is parallel to the surface (13). Each elevation (111) in the micro-structure (11) has a flank section (112) adjoining the reference plane (15), said flank section forming a uniform angle (α) with the reference plane (15). Said uniform angle (α) is in a range of approximately 33° to approximately 42° or in a range of approximately 35° to approximately 40°. The optical film (1) according to the invention allows a light fixture to have a relatively high glare suppression and at the same to produce a preferred light distribution curve (LVK). It can furthermore have a relatively flexible design and can be produced at low cost.