Optical Waveguide Non-Adhesive Light Extraction Features
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Solution Overview
Problem
Existing optical waveguides face inefficiencies in light transfer due to the use of adhesives for securing light extraction features, which reduces production throughput and increases costs while also limiting the control over light distribution and extraction efficiency.
Innovation Solution
An optical waveguide with non-adhesively bonded light extraction features on a substrate, utilizing a replication process to create a master for forming the features, allowing for precise control over light distribution and extraction without the need for adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives are used to secure light extraction features to the substrate, then the features can be fixed in position, but production throughput decreases and manufacturing costs increase
Solution Approach 1:
The patent removes the adhesive layer from the optical waveguide structure, extracting the problematic bonding medium that caused production delays and cost increases. The light extraction features are secured to the substrate through direct mechanical or optical bonding mechanisms inherent to the waveguide structure itself, eliminating the need for separate adhesive application and curing steps.
Solution Approach 2:
The optical waveguide structure is designed to self-bond the light extraction features to the substrate through its inherent structural properties. The waveguide body and substrate are configured so that the features attach directly without requiring external adhesive materials, allowing for faster, more efficient manufacturing while maintaining reliable bonding.
2Reliability
If adhesives are used to secure light extraction features, then the features can be fixed in position, but manufacturing costs increase
Solution Approach 1:
The adhesive material is completely removed from the manufacturing process. The light extraction features are secured through the waveguide's structural design alone, eliminating material costs associated with adhesives and reducing the complexity of the manufacturing process.
Solution Approach 2:
The bonding mechanism utilizes phase transitions or material property changes inherent to the waveguide structure during manufacturing. The substrate and waveguide body are processed in a way that creates strong bonds between features and substrate through controlled material transitions, replacing the need for chemical adhesives.
3Reliability
If adhesives are used to secure light extraction features, then the features can be fixed in position, but control over light distribution and extraction efficiency is limited
Solution Approach 1:
The adhesive layer that interfered with precise light distribution control is removed. The direct structural bonding allows for more accurate positioning and orientation of light extraction features, enabling better control over light extraction efficiency and distribution patterns without the optical interference that adhesives introduce.
Solution Approach 2:
The waveguide structure is designed with locally optimized bonding interfaces that provide precise positioning of light extraction features. Each feature's attachment point and orientation are carefully engineered to achieve specific light distribution characteristics, allowing for high manufacturing precision and controlled light extraction without the limitations imposed by adhesive layers.
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
This solution enhances light extraction efficiency, allows for a more controlled light distribution, and increases production efficiency by eliminating adhesive-related inefficiencies, resulting in improved luminance and illuminance patterns with reduced manufacturing costs.
Implementation Method 1
an optical waveguide mixes and directs light emitted by one or more light sources... A typical optical waveguide includes three main components: one or more coupling surfaces or elements, one or more distribution elements, and one or more extraction elements
Implementation Method 2
The elements of the waveguide coupling system can use refraction, reflection, total internal reflection, and surface or volume scattering to control the distribution of light injected into the waveguide
Implementation Method 3
The elements of the waveguide coupling system can use refraction, reflection, total internal reflection, and surface or volume scattering to control the distribution of light injected into the waveguide
Data Source
AI summary
According to one aspect, an optical waveguide comprises a waveguide body exhibiting total internal reflection, a substrate, and a plurality of light extraction features disposed on a surface of the substrate. The light extraction features are non-adhesively bonded to the waveguide body or may be disposed on opposing sides of the substrate. A method of forming an optical element is also disclosed.