Optical Sheet with Fly-Eye Lens and Diffuser Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current optical sheets, such as fly-eye lens sheets, fail to achieve desired levels of light collecting and diffusing functions, requiring multiple sheets to be used, which increases production costs and complexity, and often result in air bubbles and defects during molding.
Innovation Solution
An optical sheet design featuring first unit shaped elements forming a fly-eye lens and second unit shaped elements arranged between them, with specific geometric arrangements and proportions, along with a molding method that prevents air incorporation, ensuring high reproducibility and effective optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fly-eye lens sheet is used to provide light collecting and diffusing functions, then the optical performance is improved, but air bubbles and defects occur during molding
Solution Approach 1:
The optical sheet is divided into two distinct types of unit shaped elements: first unit shaped elements forming a fly-eye lens for light collecting, and second unit shaped elements for light diffusing. This segmentation allows each element type to be optimized for its specific function while being molded together as a single integrated sheet, eliminating the need for separate molding processes that would introduce air bubbles and defects.
Solution Approach 2:
The patent combines both light collecting and light diffusing functions into a single optical sheet by integrating first unit shaped elements (fly-eye lens) and second unit shaped elements within the same molded structure. This merging eliminates the need for multiple separate optical sheets and their associated molding processes, thereby preventing air bubbles and defects while achieving excellent optical performance.
2Reliability
If multiple optical sheets are used to achieve desired light collecting and diffusing functions, then the optical performance is improved, but production costs and device complexity increase
Solution Approach 1:
The patent merges multiple optical functions (light collecting and light diffusing) that would traditionally require separate optical sheets into a single integrated optical sheet. The sheet includes first unit shaped elements for light collecting and second unit shaped elements for light diffusing, all molded together as one component, thereby reducing device complexity and production costs while maintaining excellent optical performance.
Solution Approach 2:
The optical sheet is designed with multi-functionality by incorporating both light collecting and light diffusing capabilities within a single sheet structure. The first unit shaped elements provide light collecting function while the second unit shaped elements provide light diffusing function, allowing one optical sheet to perform the work of multiple separate sheets.
3Ease of manufacture
If traditional molding methods are used for fly-eye lens sheets, then production is simplified, but air bubbles and defects occur during molding
Solution Approach 1:
The molding process is improved by segmenting the unit shaped elements into two types with distinct geometric configurations. The first unit shaped elements (fly-eye lens) and second unit shaped elements are designed with specific shape relationships that allow molten material to flow properly during molding, preventing air entrapment and defects while maintaining manufacturing simplicity.
Solution Approach 2:
The patent optimizes geometric parameters of the unit shaped elements, including their shapes, sizes, and relative positions. By carefully controlling parameters such as the curvature radius of the first unit shaped elements and the dimensions of the second unit shaped elements, the design ensures proper material flow during molding, eliminating air bubbles and defects while keeping the manufacturing process simple.
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 achieves balanced and excellent light collecting and diffusing functions, reducing production costs and eliminating defects, while maintaining high reproducibility and optical quality.
Implementation Method 1
a light collecting sheet (light condensing sheet) that can serve to collect (condense) the light travel direction in a front direction, thereby enhancing the front brightness
Implementation Method 2
each of the unit shaped elements has a triangular, elliptical or circular shape on a cross section orthogonal to the longitudinal direction thereof. Such a light collecting sheet can serve to positively enhance the front brightness as well as can reduce in-plane variation of the front brightness
Data Source
AI summary
An optical sheet including a fly-eye lens is provided, which exhibits excellent optical functions, including desired light condensing ability, light diffusing ability and an ability for rendering a light source image substantially invisible, and can be produced with high reproducibility. The optical sheet includes a sheet-like main body, first unit shaped elements arranged on one surface of the main body and together constituting the fly-eye lens; and second unit shaped elements arranged on the one surface of the main body and extending in parallel with one direction on the sheet surface of the main body. The first unit shaped elements are arranged, with a space provided therebetween, on the one surface of the main body, while the second unit shaped elements are arranged between the first unit shaped elements on the one surface of the main body.