Optical Sheet Lens Part Shape Stability
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Solution Overview
Problem
The existing sheet-like optical members for liquid crystal display devices face challenges with deformation and cracking of unit prisms, leading to display irregularities such as white spots, particularly in large-area displays, due to issues with material hardness and processing limitations.
Innovation Solution
A sheet-like optical member is developed using an active energy ray-curable resin with specific properties, including a maximum logarithmic attenuation rate of 0.4 or less, a tangent of loss elastic modulus and storage elastic modulus of 0.2 or less, and an equilibrium elastic modulus of 1.0×10^8 Pa or more, which allows the lens part to maintain its shape and restore its original form even under external deformations, thereby preventing damage and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a material with high elastic modulus is used for the lens part to prevent deformation, then the shape stability of unit prisms is improved, but the productivity is worsened due to process restrictions
Solution Approach 1:
The invention changes the material parameters by using a resin composition with specific characteristics (weight average molecular weight of 10,000 to 1,000,000, hydroxyl value of 10 to 100 mg KOH/g) to achieve both shape stability and improved productivity, eliminating the need for excessive process restrictions
2Manufacturing precision
If excessive pressure is applied on the lens part during production to ensure shape stability, then the manufacturing precision is improved, but the reliability is worsened due to collapse or cracking of unit prisms
Solution Approach 1:
The invention provides beforehand cushioning by formulating a resin composition with appropriate molecular weight and hydroxyl value that inherently resists collapse and cracking, allowing normal manufacturing pressure without causing damage to unit prisms
3Stability of the object's composition
If the lens part is made harder to prevent deformation, then the shape stability is improved, but the ease of manufacture is worsened due to processing difficulties
Solution Approach 1:
The invention optimizes the resin composition parameters (molecular weight, hydroxyl value) to achieve the right balance between hardness for shape stability and softness for ease of processing, allowing standard manufacturing processes without special restrictions
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 solution effectively prevents the collapse and cracking of unit prisms, ensuring stable and excellent display performance without generating display irregularities like white spots, and enhances the productivity of the optical sheet production process.
Implementation Method 1
a lens part, which is formed on the substrate, is made of an active energy ray-curable resin
Data Source
AI summary
A sheet-like optical member being difficult to damage a shape of a lens part. The sheet-like optical member includes: a substrate; and a lens part, which is formed on the substrate, is made of an active energy ray-curable resin, and has a plurality of unit prisms. The maximum logarithmic attenuation rate ΔE of the lens part measured by a rigid body pendulum method is 0.4 or less.