Prismatic Optical Sheet Inversion for Reduced Reflection Losses
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Solution Overview
Problem
Conventional prismatic films in liquid crystal display backlight units suffer from reflection losses due to the air-to-polymer interface, leading to reduced light transference efficiency and increased power consumption, while also being costly and bulky.
Innovation Solution
Inverting the air-to-polymer interface to a polymer-to-air interface configuration in the prismatic optical sheet, with light-passing patterns on both surfaces and a protective layer, reduces back reflection and allows for thinner designs, improving light transference efficiency and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional air-to-polymer interface is used in prismatic films, then manufacturing is simpler, but light transference efficiency is reduced due to reflection losses
Solution Approach 1:
The patent inverts the conventional air-to-polymer interface configuration to a polymer-to-air interface. By inverting the prismatic structures so that the apexes point upward instead of downward, the light path transitions from air to polymer at the base and exits from polymer to air at the apex. This inversion eliminates the problematic air-to-polymer interface that causes reflection losses, thereby improving light transference efficiency while maintaining manufacturing simplicity.
2Use of energy by moving object
If conventional prismatic structures are used, then manufacturing is easier, but power consumption increases due to reflection losses
Solution Approach 1:
The patent applies interface inversion to eliminate reflection losses at the air-to-polymer interface. By configuring the prismatic structures with upward-pointing apexes, light travels through the polymer material and exits to air at the apex, avoiding the high-reflection air-to-polymer interface. This reduces energy loss and power consumption while the manufacturing process remains substantially unchanged.
3Length of moving object
If thicker prismatic portion is used, then manufacturing is more robust, but device thickness increases and portability is reduced
Solution Approach 1:
The patent inverts the prismatic interface configuration to eliminate reflection losses, which improves light transference efficiency. This allows for reduced prismatic portion thickness while maintaining adequate light guidance performance, thereby reducing overall device thickness and weight for improved portability.
4Loss of energy
If conventional air-to-polymer interface is used, then structure is simpler, but reflection losses increase reducing light efficiency
Solution Approach 1:
The patent inverts the prismatic structure configuration to change the interface sequence from air-to-polymer to polymer-to-air. This simple geometric inversion eliminates the reflection-prone air-to-polymer interface that light encounters in conventional designs, thereby reducing reflection losses without adding structural complexity.
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 configuration enhances light transference efficiency, reduces power consumption, and lowers manufacturing costs by minimizing reflection losses and allowing for a more compact design, thereby enabling longer battery life in portable devices.
Implementation Method 1
Incident light that strikes the sloped surfaces of these conventional underneath prismatic structures is partially reflected at the air-to-polymer interface. However, in accordance with one aspect of the present disclosure, the air-to-polymer interface is inverted so that incident light from underneath does not directly strike it when incoming, but rather exits from that inverted air-to-polymer interface (where the inverted air-to-polymer interface could be called a polymer-to-air interface, or P2A-IF for short). As a result, reflection losses are reduced and efficiency of light transference is improved
Implementation Method 2
Voids are created between the second pattern to thus create a lightpasser-to-air interface (LP2A-IF) configuration which reduces back reflection of incoming light that comes into the bottoms of the second patterns for processing thereby. In one embodiment, the second patterns provide a light converging function in a first set of parallel planes each extending in a first direction (D1).
Data Source
AI summary
An optical sheet includes a light-passing base sheet, a plurality of light-passing first patterns formed on a front major surface of the base sheet, and a plurality of light-passing second patterns formed on a rear major surface of the base sheet. The first patterns protrude from the front surface of the base sheet, a top portion of each of the second patterns makes contact with the rear surface of the second patterns while a larger lower surface of each of the second patterns is exposed to serve as a light receiving surface. Voids having relatively low refractive indices are formed between the light-passing second patterns. The optical sheet employs just one base sheet in one embodiment, thereby reducing a manufacturing cost of the optical sheet.