Ultrathin Lightguide Surface Relief Structures
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Solution Overview
Problem
Conventional lightguides are thick, rigid, and inefficient in achieving uniform light outcoupling, especially in thin and flexible applications, such as handheld devices and displays, due to limitations in optical structure size and modulation capabilities.
Innovation Solution
The development of ultra-thin lightguide elements with discrete fine optic surface relief structures on one or both surfaces, allowing for varied outcoupling modulation and flexible designs, including multi-layer configurations and roll-to-roll production methods, to achieve efficient light distribution and uniform illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional lightguide structures are used, then light distribution can be achieved, but the lightguide becomes thick and rigid
Solution Approach 1:
The lightguide structure is segmented into multiple functional layers: a thin lightguide layer for light propagation, separate outcoupling structures with surface relief features for light extraction, and distinct incoupling structures for light input. This segmentation allows each layer to be optimized independently, enabling thin overall thickness while maintaining structural functionality through the coordinated arrangement of discrete optical elements.
Solution Approach 2:
The patent employs thin film lightguide layers with integrated surface relief structures that can be manufactured using flexible roll-to-roll processes. The thin film construction inherently provides flexibility, while the surface relief features (prisms, gratings, or other optical structures) are formed directly on or within the thin film during manufacturing, ensuring the flexible lightguide maintains its optical functionality without requiring rigid support structures.
2Illumination intensity
If conventional optical structures are used, then light outcoupling can be achieved, but uniformity and modulation capability are insufficient
Solution Approach 1:
The outcoupling structures are designed with locally varied properties: different surface relief feature densities, sizes, and orientations are implemented in different regions of the lightguide to achieve spatially non-uniform light extraction patterns. This allows bright regions near light sources and dimmer regions farther away to be compensated, achieving uniform overall illumination. The incoupling structures similarly use local quality variations to optimize light capture from specific angles and directions.
Solution Approach 2:
The patent systematically varies key parameters of the optical structures including the size, shape, spacing, and orientation of surface relief features to modulate light outcoupling. By changing these parameters across different regions and layers, the system achieves precise control over light distribution uniformity and intensity modulation without requiring complex additional optical components.
3Illumination intensity
If multiple light sources are used to achieve uniform illumination, then illumination quality improves, but assembly complexity and cost increase
Solution Approach 1:
The patent extracts the light redistribution function from the light sources themselves and transfers it to passive optical structures (incoupling and outcoupling elements) that manipulate light after it enters the lightguide. This allows a single or minimal number of light sources to be used, while the optical structures perform the work of achieving uniform illumination through refraction, reflection, and diffraction, thereby simplifying assembly while maintaining illumination quality.
Solution Approach 2:
The lightguide layer acts as an intermediary medium between the light sources and the final illumination field. It receives light from minimal sources and uses integrated surface relief structures to redistribute and uniformize the light before output. This intermediary function eliminates the need for multiple light sources or complex lens arrays, as the lightguide itself performs the light management function through its engineered optical structures.
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 provides a thin, flexible, and cost-effective lightguide solution that efficiently manages light distribution, reducing the need for multiple light sources and assembly complexity, while enabling uniform illumination and adaptability in various applications.
Implementation Method 1
a lightguide element including one lightguide layer comprising a plurality of discrete fine optic surface relief structures on at least one portion of at least one surface
Implementation Method 2
Each surface relief structure includes basic structural features on the order of about 10 microns or less in height, and on the order of about 10 microns or less in each lateral dimension
Data Source
AI summary
An ultra thin lighting element including at least one light source. A lightguide element includes one lightguide layer comprising a plurality of discrete fine optic surface relief structures on at least one portion of at least one surface. Each surface relief structure includes basic structural features on the order of about 10 microns or less in height, and on the order of about 10 microns or less in each lateral dimension. The number, arrangement and size of each surface relief structure and height and lateral dimensions of the structural features of the surface relief structures being varied to provide a desired degree of outcoupling modulation of light incoupled into the light guide element.