Optical Sheet with Elastic Resin Prism Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical sheets for liquid crystal displays (LCDs) are prone to damage from external impacts, leading to reduced brightness and increased production costs due to the fragility of their prism structures, which also complicates handling and manufacturing processes.
Innovation Solution
An optical sheet with a cured layer of resin, composed of a curable resin composition that includes specific compounds with high elastic recovery rates, providing flexibility and resistance to external impacts without the need for protective films, and featuring a structured surface with three-dimensional patterns that can withstand compressive forces without sustaining damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a prism structure is used to improve brightness in the front direction, then brightness is improved, but the upper part of the peak is readily broken or worn away by external scratches, causing damage to the prism structure
Solution Approach 1:
The patent changes the material parameters of the prism structure by using a resin composition with specific elastic properties (elastic recovery rate of 80% or more). This allows the prism peaks to be softer and more resistant to scratching while maintaining the brightness-enhancing function. The elastic recovery property enables the peaks to return to their original shape after deformation, preventing permanent damage from external impacts.
Solution Approach 2:
The patent employs a composite resin composition containing multiple components: a resin main chain (polyester or polyamide), a resin side chain (acrylic or methacrylic groups), and a silane crosslinking agent. This composite material structure provides both the optical properties needed for brightness enhancement and the mechanical properties required for scratch resistance and impact durability.
2Illumination intensity
If the power of the backlight unit is increased to increase brightness, then brightness is improved, but power consumption becomes larger and power loss by heat becomes larger
Solution Approach 1:
The patent segments the light guidance function into multiple prism structures arranged in arrays. Each prism acts as an individual light-guiding element that redirects light toward the front direction. This segmentation allows for more efficient light utilization compared to a single large light source, reducing overall power consumption while maintaining high brightness.
Solution Approach 2:
The patent replaces the mechanical approach of increasing backlight power with an optical mechanism - the prism structure - to redirect and concentrate light. This substitution allows the system to achieve high brightness without proportionally increasing power consumption, as the prisms efficiently guide available light rather than requiring additional energy input.
3Reliability
If a protective film is stacked to prevent damage to prism structures, then resistance to external impact is improved, but the production process becomes more complex and production cost increases
Solution Approach 1:
The patent makes the prism structure itself self-protecting by incorporating scratch-resistant properties directly into the resin composition. The elastic recovery capability and scratch resistance are inherent properties of the prism material, eliminating the need for separate protective films. This self-service approach simplifies the production process while maintaining reliability.
Solution Approach 2:
The patent merges the protective function into the prism structure itself by using a resilient resin composition with high elastic recovery properties. Instead of having a separate protective layer, the protective characteristics are combined with the optical function in a single integrated component, reducing overall device complexity and manufacturing steps.
4Illumination intensity
If several sheets and films are stacked during manufacture to increase brightness, then brightness is improved, but the upper portion of the lower prism film comes in contact with the lower portion of the upper prism film, causing damage to the prism structure
Solution Approach 1:
The patent changes the mechanical parameters of the prism films to be more compliant and less prone to damage during stacking operations. The high elastic recovery rate (80% or more) allows the films to deform and recover without sustaining permanent damage, enabling safer handling and stacking processes while maintaining the brightness-enhancing function.
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 prevents damage from external impacts, maintains brightness, simplifies production by eliminating the need for protective films, and reduces failure rates and production costs while enhancing handling and reliability.
Implementation Method 1
a cured layer of resin whose surface is structured and which is made of a curable resin composition comprising a compound of the following formula (1)... the elastic recovery rate of the optical sheet, which is represented by the following equation, is more than 80% as measured when pressing the upper side of the structured surface with a flat tip
Implementation Method 2
the elastic recovery rate of the optical sheet, which is represented by the following equation, is more than 80% as measured when pressing the upper side of the structured surface with a flat tip at a pressing speed of 0.2031 mN/sec to a maximum compressive force of 1 gf or 2 gf, maintaining the structured surface at the maximum compressive force for 5 seconds
Data Source
AI summary
Disclosed is an optical sheet which is used in a liquid crystal display. The optical sheet is not readily damaged by external impact, and thus is easy to handle and can reduce failure rate, leading to a decrease in production cost and an increase in production efficiency. Also, it can prevent a decrease in brightness.