Sea-Island Light Control Filter with Flexible Elastomer Sea Portion
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Solution Overview
Problem
The existing light control films suffer from reduced light transmission due to the presence of a land film containing light-absorbing material, which also leads to air bubbles in the manufacturing process, and are prone to cracks and chips during the curing process due to the brittleness of the photocurable resin, necessitating a support layer, while there is a demand for a thinner, single-layer light control body.
Innovation Solution
A light control filter with a sea-island structure where the light-transmitting and light-shielding portions extend through the film, featuring a sea portion with an MD-1 rubber hardness of 25-80, primarily composed of elastomer, allowing for high flexibility and elimination of the need for a support layer, enabling handling as a single layer and reducing device thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a land film is formed on the bottom surface of recesses in the manufacturing process, then the support layer can be easily laminated, but light transmission is reduced and air bubbles remain in the recess
Solution Approach 1:
The invention extracts and removes the land film from the bottom surface of the recesses through a specific manufacturing process involving pouring liquid photocurable resin, curing it, and then removing the land film portion. This eliminates the light-absorbing barrier while maintaining the structural integrity needed for support layer lamination.
Solution Approach 2:
Instead of accepting the land film as an inevitable byproduct, the invention inverts the approach by deliberately forming the land film and then removing it. This reversal allows the process to achieve both easy lamination (through temporary land film formation) and high light transmission (through subsequent removal).
2Manufacturing precision
If photocurable resin is used to form the microstructured layer, then the light control film can be manufactured with precise microstructure, but cracks and chips occur during curing due to brittleness
Solution Approach 1:
The invention applies beforehand cushioning by forming a support layer that provides mechanical strength and flexibility to the brittle microstructured layer. This support layer acts as a cushioning element that prevents cracks and chips during the curing process and handling, while allowing the microstructured layer to maintain its precise optical structure.
Solution Approach 2:
The invention uses composite materials by combining the brittle photocurable resin microstructured layer with a flexible support layer material. This composite structure leverages the optical precision of the photocurable resin while the support layer provides mechanical strength and flexibility, preventing cracks and chips.
3Strength
If a support layer is laminated to prevent cracks and chips, then mechanical strength is improved, but the device thickness increases
Solution Approach 1:
The invention employs a thin flexible support layer that provides sufficient mechanical strength to prevent cracks and chips while minimizing thickness addition. The flexible nature of this thin film allows it to provide protection without the bulk that would result from using rigid support structures.
4Length of stationary object
If the light control film is designed as a single layer without support layer, then device thickness is reduced, but handling becomes difficult due to brittleness
Solution Approach 1:
The invention uses a flexible support layer in thin film form that provides the necessary mechanical properties for easy handling and flexibility. This thin flexible film allows the light control film to be handled as a single layer unit while preventing brittleness-related issues during operation and installation.
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 enhances light transmission and flexibility, allowing the light control filter to be handled as a single layer without a support layer, thereby reducing thickness and improving device integration, while maintaining mechanical strength and optical properties.
Implementation Method 1
the sea portion has an MD-1 rubber hardness of 25 or more and 80 or less
Data Source
AI summary
A light control filter includes a sheet having a sea-island structure including a light-transmitting portion and a light-shielding portion, wherein the light-transmitting portion and the light-shielding portion each extend from a first principal surface to a second principal surface, wherein any one of the light-transmitting portion and the light-shielding portion forms a plurality of island portions configured to penetrate through the sheet from the first principal surface to the second principal surface, and another of the light-transmitting portion and the light-shielding portion forms a sea portion configured to separate the plurality of island portions from one another, and wherein the sea portion has an MD-1 rubber hardness of 25 or more and 80 or less.