Display including a film lightguide bent around a guide element

• US 10,191,199 B2
• Filed: 06/09/2017
• Issued: 01/29/2019
• Est. Priority Date: 03/12/2013
• Status: Active Grant

• Current Assignee: FLEx Lighting II, LLC
• Original Assignee: FLEx Lighting II, LLC
• Inventors: Nichol, Anthony, Coleman, Zane
• Primary Examiner(s): Hollweg, Thomas A
• Application Number:
  US15/618,336
• Publication Number:
  US 20170285243A1
• Time in Patent Office: 599 Days
• Field of Search: 385 31- 32, 385129-130, 362600-629
• CPC Class Codes: G02B 6/0025 Diffusing sheet or layer; Prismatic sheet or layer
• CPC Class Codes: G02B 6/0028 Light guide, e.g. taper
• CPC Class Codes: G02B 6/0031 Reflecting element, sheet or layer
• CPC Class Codes: G02B 6/0033 Means for improving the coupling-out of light from the light guide
• CPC Class Codes: G02B 6/0035 provided on the surface of the light guide or in the bulk of it
• CPC Class Codes: G02B 6/0045 by shaping at least a portion of the light guide
• CPC Class Codes: G02B 6/0051 Diffusing sheet or layer
• CPC Class Codes: G02B 6/0058 varying in density, size, shape or depth along the light guide
• CPC Class Codes: G02B 6/0065 Manufacturing aspects; Material aspects
• CPC Class Codes: G02B 6/009 of the light source in the package G02B6/0021 takes precedence
• CPC Class Codes: G02F 1/133606 including a specially adapted diffusing, scattering or light controlling members

Abstract

In one aspect, a display comprises a light source, a film-based lightguide with a light emitting region positioned adjacent to and directing light to an active area of a spatial light modulator in a thickness direction. The film may have a light mixing region positioned between a light input region and the light emitting region. In one aspect the display comprises a guide element having a surface curved in a first plane positioned along a first edge of the spatial light modulator, wherein the film is folded along the curved surface at a first fold such that the first fold positions a portion of the light mixing region above or below the active area, the light mixing region comprises the first fold, and an inner surface of the film in the light mixing region is in contact with and curved along the curved surface of the guide element.

Claims

1. A display comprising:

a light source;

a spatial light modulator with a first outer surface and an active area;

a film including a body having an inner surface and an opposing outer surface in a thickness direction of the film, the body of the film comprising a light emitting region defined by a plurality of light extracting features, the light emitting region is positioned adjacent the active area of the spatial light modulator in the thickness direction and is substantially parallel to the first outer surface of the spatial light modulator;

a light input region of the film configured to receive light emitted from the light source;

a light mixing region of the film positioned along the film between the light input region and the light emitting region such that the light emitted from the light source propagates by total internal reflection from the light input region, through the light mixing region, and into the light emitting region in a total internal reflection condition, wherein the light extracting features redirect a portion of the light out of the film in the light emitting region toward the spatial light modulator; and

a guide element positioned along a first edge of the spatial light modulator, the guide element having a surface curved in a first plane comprising the thickness direction of the film, wherein

the film is folded along the curved surface of the guide element at a first fold in the first plane such that the first fold positions a portion of the light mixing region above or below the active area of the spatial light modulator in the thickness direction;

the light mixing region comprises the first fold; and

the inner surface of the film in the light mixing region is curved along the curved surface of the guide element at the first fold and is in contact with the curved surface at the first fold.

2. The display of claim 1 wherein the curved surface of the guide element subtends an angle greater than 90 degrees at the first fold.

3. The display of claim 2 wherein the cross-sectional shape in the first plane of the curved surface of the guide element at the first fold comprises all or a portion of an ellipse or circle.

4. The display of claim 2 wherein the curved surface of the guide element has an average radius of curvature in the first plane at the first fold less than 2 millimeters.

5. The display of claim 1 wherein the inner surface of the film along the curved surface of the guide element at the first fold comprises a radius of curvature that is not less than a radius of curvature of the curved surface of the guide element at the first fold.

6. The display of claim 5 wherein the film comprises a core layer and a cladding layer, the emitted light from the light source propagates by total internal reflection in the core layer, and the curved surface of the guide element has an average radius of curvature in the first plane at the first fold greater than 4 times an average thickness of the core layer at the first fold.

7. The display of claim 1 wherein the curved surface of the guide element subtends an angle greater than 45 degrees at the first fold.

8. The display of claim 1 wherein the curved surface of the guide element subtends an angle between 80 degrees and 270 degrees at the first fold.

9. The display of claim 1 wherein the curved surface of the guide element has an average radius of curvature in the first plane at the first fold greater than 0.5 times a thickness of the spatial light modulator in the first plane.

10. The display of claim 1 wherein the film comprises a core layer and a cladding layer, the emitted light from the light source propagates by total internal reflection in the core layer, and the cladding layer is positioned between the core layer and the spatial light modulator.

11. The display of claim 10 wherein the cladding layer comprises an adhesive that adheres the light mixing region of the film to the guide element at the first fold.

12. The display of claim 1 wherein the film further includes a plurality of coupling lightguide strips extending from the light mixing region of the film, the coupling lightguides strips are folded and stacked such that ends of the folded and stacked coupling lightguide strips define the light input region.

13. The display of claim 1 wherein the light source is positioned above or below the active area of the spatial light modulator in the thickness direction.

14. The display of claim 1 wherein a cross-section of the guide element at the curved surface of the guide element at the fold in the first plane is substantially constant in a direction perpendicular to the first plane.

15. The display of claim 1 wherein the guide element has a length along the first edge of the spatial light modulator orthogonal to the first plane that is greater than 3 times a width of the guide element in the first plane.

16. A display comprising:

a light source;

a reflective spatial light modulator with a first outer surface and an active area;

a film including a body having an inner surface and an opposing outer surface in a thickness direction of the film, the body of the film comprising a light emitting region defined by a plurality of light extracting features, the light emitting region is positioned above the active area of the reflective spatial light modulator in the thickness direction;

a light input region of the film configured to receive light emitted from the light source;

a light mixing region of the film positioned along the film between the light input region and the light emitting region such that the light emitted from the light source propagates by total internal reflection from the light input region, through the light mixing region, and into the light emitting region, wherein the light extracting features redirect a portion of the light out of the film in the light emitting region toward the reflective spatial light modulator; and

a guide element positioned along a first edge of the reflective spatial light modulator, the guide element having a surface curved in a first plane comprising the thickness direction of the film, wherein

the film is folded along the surface of the guide element at a first fold in the first plane such that the first fold positions a portion of the light mixing region below the active area of the spatial light modulator in the thickness direction;

the light mixing region comprises the first fold; and

the inner surface of the film in the light mixing region is curved along the curved surface of the guide element at the first fold.

17. The display of claim 16 wherein the curved surface of the guide element subtends an angle greater than 90 degrees at the first fold and has an average radius of curvature in the first plane at the first fold less than 2 millimeters.

18. A method of making a display comprising:

a) forming a film including a body having an inner surface and an opposing outer surface in a thickness direction of the film, the body of the film comprising a light emitting region defined by a plurality of light extracting features and a light mixing region adjacent the light emitting region along the film;

b) positioning the light emitting region of the film adjacent an active area of the spatial light modulator in the thickness direction and substantially parallel to the first outer surface of the spatial light modulator;

c) positioning a light source to emit light into a light input region of the film such that the light emitted from the light source passes through the light mixing region of the film and into the light emitting region in a total internal reflection condition, wherein the light extracting features redirect a portion of the light out of the film in the light emitting region toward the spatial light modulator;

d) positioning a guide element along a first edge of the spatial light modulator, the guide element having a surface curved in a first plane comprising the thickness direction of the film; and

e) folding the light mixing region of the film along the curved surface of the guide element at a first fold in the first plane such that the folding positions a portion of the light mixing region above or below the active area of the spatial light modulator in the thickness direction.

19. The method of claim 18 wherein folding the light mixing region comprises bending the inner surface of the film in the light mixing region along the curved surface of the guide element at the first fold such that the inner surface is in contact with the curved surface of the guide element at the first fold.

20. The method of claim 18 wherein the spatial light modulator is a reflective spatial light modulator, positioning the light emitting region of the film positions the light emitting region above the reflective spatial light modulator in the thickness direction, and folding the light mixing region positions a portion of the light mixing region below the active area of the spatial light modulator in the thickness direction.