Slanted Microlouver Manufacturing via Angled Exposure

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Solution Overview

Problem

Existing methods for manufacturing microlouvers result in density distribution in transparent resin layers and mechanical strain, leading to reduced yields and non-flat interface surfaces, which affect light distribution characteristics and the overall quality of the optical elements.

Innovation Solution

A method involving the alternate arrangement of transparent and light-absorbing layers, where exposure light is applied at an angle to form slanted transparent layers without heat or pressure, allowing the light-absorbing layer to be filled with a black curable resin to restrict light emission, ensuring uniform density and flat interfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If heat and pressure are applied to flatten a curved microlouver member to slant the light absorbing layer, then light distribution characteristics can be customized, but density distribution occurs in the transparent resin layer and mechanical strain is induced

Engineering Contradiction:

Improvelight distribution characteristicsVSAvoiddensity uniformity and interface flatness

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The transparent resin layer is formed with a predetermined slanted shape before the light absorbing layer is applied. This preliminary formation of the slanted transparent layer eliminates the need for subsequent heat and pressure treatment, preventing density distribution and mechanical strain while maintaining customized light distribution characteristics

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical process of curving and flattening the microlouver member under heat and pressure is replaced by a direct patterning process where the transparent resin layer is formed with the desired slanted shape from the beginning, substituting mechanical transformation with a more precise formation method

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If mechanical transformation under heat and pressure is used to slant the light absorbing layer, then light distribution can be controlled, but the microlouver may be damaged resulting in low yields

Engineering Contradiction:

Improvelight distribution controlVSAvoidmanufacturing yield

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The transparent resin layer is patterned with the final slanted shape before assembling the light absorbing layer, eliminating the need for subsequent mechanical transformation that could damage the microlouver and reduce manufacturing yield

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The harsh mechanical transformation process under heat and pressure is replaced by a gentler patterning process using a mask and exposure light, which forms the slanted transparent layer without risking damage to the optical element

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If the microlouver member is curved and then flattened under pressure, then the light absorbing layer can be slanted for customized light distribution, but the interface surface between layers becomes non-flat

Engineering Contradiction:

Improvecustomized light distributionVSAvoidinterface surface flatness

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The transparent resin layer is formed with the predetermined slanted shape before the light absorbing layer is applied, ensuring that the interface surface between the two layers remains flat while achieving customized light distribution through the slanted transparent layer geometry

Inventive Principle:

Principle #10Preliminary action

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 approach prevents density changes in the transparent layer and reduces mechanical strain, enhancing yield and maintaining flat interfaces, thus achieving predetermined light distribution characteristics without damaging the optical elements.

Implementation Method 1

applying an exposure light to the transparent photosensitive resin through the mask to form a transparent layer

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

the light absorbing layer restricts the range of light transmitted through the transparent layer in the light emitting direction

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Data Source

PatentUS7916241B2Method for manufacturing optical element

Publication Date: 2011.03.29 NEC LCD TECH CORP

AI summary

An optical element manufacturing method according to the present invention includes: disposing a mask on a transparent photosensitive resin; patterning said transparent resin by applying an exposure light to said transparent photosensitive resin through said mask to form a transparent layer; forming a light absorbing layer by filling a gap in the transparent layer with a black curable resin; and illuminating a mask surface of the mask with the exposure light at an angle.