Optical Film with Segmented Protrusions for Brightness Retention
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Solution Overview
Problem
Laminated optical films used in LCD modules face issues with brightness deterioration due to adhesion between diffuser and prism sheets, requiring a solution that maintains strength while enhancing light diffusion and minimizing deformation.
Innovation Solution
An optical film design featuring a first prism sheet, a second prism sheet, and a diffuser sheet with specific protrusion heights and diameters, where the diffuser sheet is adhered to the first prism sheet and the second prism sheet is adhered to the diffuser sheet, creating an air gap to prevent brightness deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If diffuser sheet and prism sheet are laminated to improve reliability and strength, then film strength is improved, but brightness is deteriorated
Solution Approach 1:
The diffuser sheet is divided into multiple regions with different protrusion heights (first protrusions with height h1 and second protrusions with height h2 where h1 > h2). This segmentation allows different areas to serve different functions: higher protrusions maintain strength and adhesion, while lower protrusions reduce light scattering and maintain brightness.
Solution Approach 2:
Different regions of the diffuser sheet are given different local properties through varying protrusion heights. The first protrusions (taller) provide stronger adhesion and structural support, while the second protrusions (shorter) minimize light diffusion interference. This local differentiation resolves the contradiction between strength and brightness by optimizing each region for its specific function.
2Stability of the object's composition
If diffuser sheet and prism sheet are laminated closely to maintain film compactness, then film deformation is minimized, but light diffusion is reduced and brightness deteriorates
Solution Approach 1:
The diffuser sheet is segmented into regions with different protrusion heights, creating a hierarchical structure. The taller first protrusions maintain structural stability and compactness, while the shorter second protrusions allow sufficient light diffusion space, thus resolving the contradiction between compactness and light diffusion.
Solution Approach 2:
The solution moves from a two-dimensional flat lamination to a three-dimensional structured lamination with varying protrusion heights. This dimensional change allows the film to maintain compactness in the horizontal plane while creating vertical space for light diffusion, effectively resolving the contradiction between compactness and light diffusion capability.
3Strength
If adhesive material is applied between sheets to ensure strong bonding, then film strength is improved, but light diffusion capability is reduced and brightness deteriorates
Solution Approach 1:
The adhesive application is segmented into two distinct patterns: first adhesive portions applied to the base film and second adhesive portions applied to the prism sheet. This segmentation allows optimized adhesive distribution that maintains strong bonding while preserving light diffusion paths, resolving the contradiction between adhesion strength and brightness.
Solution Approach 2:
The diffuser sheet with its structured protrusions acts as an intermediary element between the base film and prism sheet. The varying protrusion heights create controlled air gaps that mediate between the adhesive bonding requirement and the light diffusion requirement, allowing both functions to coexist effectively.
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 design enhances light diffusion and maintains film strength, minimizing brightness loss and ensuring a clear, bright LCD panel by optimizing the relationship between protrusion heights and diameters, specifically within the range of 0.25≤x≤0.6 for the height ratio and z≥0.15 for the diameter ratio, thereby improving the optical film's performance.
Implementation Method 1
an optical film which can diffuse light emitted from a light source assembled in a light guide plate module
Implementation Method 2
the diffuser sheet is adhered to the first prism sheet by an adhesive material and the first prism sheet is also adhered to the second prism sheet by an adhesive material
Data Source
AI summary
Disclosed is an optical film includes a first prism sheet including a plurality of first prisms arranged on one side of the first prism sheet, a second prism sheet including a plurality of second prisms arranged on one side of the second prism sheet, and a diffuser sheet including a plurality of first protrusions and a plurality of second protrusions arranged on one side of the diffuser sheet. The optical film is prepared to have a height of the first protrusions being greater than a height of the second protrusions. The optical film is further prepared that the first prism sheet, the second prism sheet and the diffuser sheet laminated where the first protrusions of the diffuser sheet is adhered to a side of the first prism sheet where no first prisms are arranged, and the first prisms of the first prism sheet are adhered to a side of the second prism sheet where no second prisms are arranged.