Multilayer Optical Sheet Module Bonding Rigidity
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Solution Overview
Problem
Conventional multilayer optical sheet modules in liquid crystal display devices face issues with bonding rigidity and durability due to limited adhesive area, leading to potential separation of optical sheets and reduced product yield, as well as brightness reduction caused by light refraction in the bonding area.
Innovation Solution
A multilayer optical sheet module design featuring an upper optical sheet with a first structural pattern and a lower optical sheet with a second structural pattern, where the second structural pattern includes a light transmitting part with a traverse cross section that decreases along the upward direction and an embedded part with a larger circumference in the adhesion layer, optimizing the bonding area and refractive properties to enhance bonding quality and brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the optical sheets are bonded using a conventional adhesion layer, then the bonding process is simple, but the bonding area is limited and bonding rigidity deteriorates
Solution Approach 1:
The patent transitions from a conventional planar adhesion layer to a three-dimensional protruding structure. The lower optical sheet features protrusions that extend upward into the adhesion layer, creating vertical dimensionality. This dimensional change significantly increases the bonding interface area and improves bonding rigidity without complicating the bonding process
Solution Approach 2:
The protrusions of the lower optical sheet are embedded within the adhesion layer, creating a nested configuration. The adhesion layer surrounds and embeds the protrusions, maximizing the contact area between the bonding materials. This nesting approach ensures strong mechanical interlocking and enhanced bonding strength
2Reliability
If the adhesion layer thickness is increased to improve bonding, then bonding quality improves, but light refraction increases and brightness deteriorates
Solution Approach 1:
The adhesion layer is segmented into different functional zones: a thicker region that surrounds and embeds the protrusions for strong bonding, and a thinner region at the top surface that minimizes light refraction. This segmentation allows the adhesion layer to simultaneously provide strong bonding and maintain optical performance
Solution Approach 2:
Different thicknesses of the adhesion layer are applied to different locations based on functional requirements. The region contacting the protrusions has greater thickness for bonding, while the region exposed to light has lesser thickness for optical performance. This local differentiation resolves the contradiction between bonding quality and brightness
3Reliability
If the structural pattern is simplified to reduce manufacturing complexity, then manufacturing is easier, but bonding area is reduced and durability deteriorates
Solution Approach 1:
The protrusions feature curved surfaces instead of sharp angular geometries. This curvature simplifies the molding process and manufacturing while still providing effective bonding area. The rounded shapes are easier to manufacture than complex angular patterns while maintaining the essential function of increasing bonding interface
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 optimized bonding area and refractive properties improve the durability and bonding quality of the optical sheet module, while minimizing brightness reduction, resulting in enhanced performance and increased product reliability.
Implementation Method 1
an adhesion layer provided between the upper optical sheet and the lower optical sheet
Implementation Method 2
The first optical sheet refracts and concentrates the light incident from the diffusion sheet so that the incident light enters vertically into a surface of a second optical sheet
Data Source
AI summary
There is disclosed a multilayer optical sheet module including an upper optical sheet comprising a first structural pattern projected upward; a lower optical sheet disposed under the upper optical sheet, the lower optical sheet comprising a second structural pattern projected toward the upper optical sheet; and an adhesion layer provided between the upper optical sheet and the lower optical sheet, wherein the second structural pattern includes a light transmitting part having a traverse cross section getting smaller along an upward direction; and an embedded part continuously connected to an upper portion of the light transmitting part, with a predetermined portion embedded in the adhesion layer, and a circumference of a cross section possessed by the embedded part, contacting with the adhesion layer, is larger than a circumference of a virtual cross section locus formed by extending the light transmitting part upward, with a continuous slope.