Optical Structure Protective Film for Moisture Isolation and Anti-Reflection
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Solution Overview
Problem
Optical elements with pancake structures face issues of water absorption, corrosion, and optical property deterioration due to exposure to moisture and oxygen, which conventional anti-reflective coatings fail to address effectively.
Innovation Solution
An optical structure with a light-transmitting protective film having a stacked first and second structure, where the second structure exposed to air features microstructures with a feature size not exceeding the working wavelength, isolating the optical element from moisture and oxygen while maintaining anti-reflection performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional anti-reflective coating is applied to the optical element, then the reflection is reduced, but the protection against moisture and oxygen is insufficient
Solution Approach 1:
The protective film is divided into multiple layers: a first structure (dense barrier layer) and a second structure (microstructure layer with air pockets). This segmentation allows each layer to perform its specific function - the first structure provides moisture and oxygen barrier, while the second structure provides anti-reflection through refractive index gradient.
Solution Approach 2:
The protective film uses composite structure combining dense material in the first structure for barrier properties and air-filled microstructures in the second structure for optical properties. This composite approach simultaneously achieves both protection against harmful environmental factors and reduced reflection.
2Reliability
If a dense protective film is applied to isolate moisture and oxygen, then the reliability is improved, but the optical transmission is reduced due to increased reflection
Solution Approach 1:
Different regions of the protective film have different properties: the first structure has high density for barrier function, while the second structure has low density with air pockets for optical function. This local differentiation allows simultaneous achievement of both protection and anti-reflection.
Solution Approach 2:
The solution transitions from a single-layer uniform structure to a multi-layer structured film with vertical differentiation. The first structure provides barrier function while the second structure with microstructures provides anti-reflection, achieving both functions through dimensional organization.
3Object-affected harmful factors
If the feature size of microstructures is reduced to enhance anti-reflection, then the optical performance is improved, but the manufacturing precision requirement increases
Solution Approach 1:
The patent specifies that the feature size of microstructures should be 1/10 to 1/5 of the working wavelength (e.g., 10-300 nm for visible light). This parameter optimization balances anti-reflection effectiveness with manufacturing feasibility, avoiding excessively small dimensions that would be difficult to control.
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 structure effectively isolates the optical element from environmental moisture and oxygen, preserving its original optical properties and preventing deterioration, while providing anti-reflection capabilities.
Implementation Method 1
a water vapor transmission rate of the first structure is ≤1 g·mm/(m2·24 h)
Implementation Method 2
at least part of the microstructures have a pitch of a feature size in a direction parallel to a surface, of the first structure, in contact with the optical element, and the feature size is not greater than a working wavelength of the optical element
Implementation Method 3
a refractive index of the first structure is greater than an equivalent refractive index of the second structure
Data Source
AI summary
An optical structure and a manufacturing method thereof, and a display apparatus are provided. The optical structure includes an optical element and a light-transmitting protective film. The optical element includes a first surface and a second surface. The light-transmitting protective film is between the optical element and air, and is in contact with the optical element. The optical element includes a lens structure including a first lens surface and a second lens surface, a transflective film, a reflective polarizing film, and a phase retardation film. The light-transmitting protective film includes a first structure and a second structure in contact with air, the compactness of the first structure is greater than that of the second structure, the second structure includes microstructures having a pitch not greater than a working wavelength of the optical element.