Optical Sheet With Complementary Corrugated Resin Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical sheets with uniform pattern arrangements suffer from moiré interference, leading to reduced image quality in display devices, and the process of tilting these patterns to minimize moiré is inefficient and increases manufacturing costs.
Innovation Solution
An optical sheet comprising multiple resin layers with complementary surface corrugations, where each layer has a specific surface roughness and pattern design to minimize moiré and enhance viewing angle and contrast ratio characteristics, is proposed. The manufacturing method involves imprinting resins using pattern molds to form the corrugated surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fine patterns are formed in a uniform arrangement to achieve various optical characteristics, then optical functions are improved, but a large number of defects occur during pattern mold processing
Solution Approach 1:
The patent applies asymmetry by tilting the fine patterns at a predetermined angle (e.g., 45 degrees) relative to the pixel arrangement direction. This asymmetric orientation prevents the formation of moiré patterns while maintaining the optical characteristics, and also reduces processing defects during pattern mold fabrication by avoiding horizontal and vertical alignments that cause issues.
2Reliability
If the arrangement direction of fine patterns is tilted at a predetermined angle to minimize moiré effect, then image quality is improved, but productivity of the optical sheet is greatly reduced
Solution Approach 1:
The patent changes the orientation parameter of the fine patterns by tilting them at a predetermined angle (such as 45 degrees) relative to the pixel arrangement direction. This parameter change effectively minimizes moiré effects while the patent simultaneously addresses productivity concerns through optimized manufacturing processes that can handle tilted patterns efficiently.
3Reliability
If an optimal tilt angle is varied depending on display device specifications, then moiré is minimized, but manufacturing costs are greatly increased
Solution Approach 1:
The patent employs parameter changes by adjusting the tilt angle of fine patterns according to specific display device requirements. This allows optimization of moiré minimization for different applications while maintaining manufacturing feasibility through systematic approach to angle selection and mold design.
4Reliability
If fine patterns having size from tens of nm to hundreds of nm are formed to achieve various optical characteristics, then optical functions are improved, but the patterns are difficult to process without defects
Solution Approach 1:
The patent applies asymmetry by orienting fine patterns at a predetermined angle (e.g., 45 degrees) relative to the pixel arrangement direction. This asymmetric configuration simplifies the processing of sub-100nm patterns by avoiding the alignment issues that arise with horizontal and vertical orientations, while still achieving the desired optical characteristics.
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 sheet effectively minimizes moiré and sparkling defects, improving image quality and reducing manufacturing costs by optimizing the design and process of the optical sheet layers.
Implementation Method 1
The first resin layer includes a first one-surface corrugated portion formed on one surface thereof and having a plurality of convex portions and concave portions, the second resin layer includes a second other-surface corrugated portion formed on the other surface thereof and having a pattern shape complementary to that of the first one-surface corrugated portion
Implementation Method 2
The second resin layer includes a second one-surface corrugated portion formed on one surface thereof, having a plurality of convex portions and concave portions and having a surface roughness value greater than that of the first one-surface corrugated portion
Data Source
AI summary
An optical sheet and a method for manufacturing the optical sheet are provided. The optical sheet comprises: a first substrate; a first resin layer disposed on one surface of the substrate; a second resin layer disposed on one surface of the first resin layer; and a third resin layer disposed on one surface of the second resin layer, wherein the first resin layer includes a first one-surface corrugated portion formed on one surface thereof and having a plurality of convex portions and concave portions, the second resin layer includes a second other-surface corrugated portion formed on the other surface thereof and having a pattern shape complementary to that of the first one-surface corrugated portion, the second resin layer includes a second one-surface corrugated portion formed on one surface thereof, having a plurality of convex portions and concave portions and having a surface roughness value greater than that of the first one-surface corrugated portion, and the third resin layer has a third other-surface corrugated portion formed on the other surface thereof and having a pattern shape complementary to that of the second one-surface corrugated portion.