Backlight unit with controlled light extraction

• US 10,261,233 B2
• Filed: 11/25/2014
• Issued: 04/16/2019
• Est. Priority Date: 11/25/2014
• Status: Active Grant

• Current Assignee: Microsoft Technology Licensing LLC (Microsoft Corporation)
• Original Assignee: Microsoft Technology Licensing LLC (Microsoft Corporation)
• Inventors: Large, Timothy
• Primary Examiner(s): Nguyen, Lauren
• Application Number:
  US14/552,762
• Publication Number:
  US 20160147006A1
• Time in Patent Office: 1,603 Days
• CPC Class Codes: G02B 6/0036 2-D arrangement of prisms, protrusions, indentations or roughened surfaces
• CPC Class Codes: G02B 6/0053 Prismatic sheet or layer; Brightness enhancement element, sheet or layer
• CPC Class Codes: G02B 6/0055 Reflecting element, sheet or layer

Abstract

A backlight unit includes a light guide layer including a plurality of extraction features disposed along a rear face of the light guide layer, a first cladding layer adhesively secured to the rear face of the light guide layer, a plurality of turning structures disposed along the first cladding layer, and a second cladding layer adhesively secured to a front face of the light guide layer. The first cladding layer has a first refractive index lower than a guide refractive index of the light guide layer. The second cladding layer has a second refractive index lower than or equal to the first refractive index.

Claims

1. A backlight unit comprising:

a light guide layer having a front face and a rear face, the light guide layer comprising a plurality of extraction features disposed along the rear face of the light guide layer, each extraction feature having a face oriented at an angle relative to the rear face;

a first cladding layer adhesively secured to the rear face of the light guide layer;

a plurality of turning structures disposed along the first cladding layer; and

a second cladding layer adhesively secured to the front face of the light guide layer;

wherein the first cladding layer has a first refractive index lower than a guide refractive index of the light guide layer, and

wherein the second cladding layer has a second refractive index lower than the first refractive index such that the front face has a total internal reflection angle greater than a total internal reflection angle of the rear face by at least twice the angle of the face of each extraction feature.

2. The backlight unit of claim 1, wherein each extraction feature of the plurality of extraction features comprises a respective indentation in the rear face of the light guide layer.

3. The backlight unit of claim 2, wherein each indentation comprises a prism shallower than each turning structure of the plurality of turning structures.

4. The backlight unit of claim 2, wherein:

the first cladding layer is composed of an adhesive material having the first refractive index; and

each indentation is filled with the adhesive material.

5. The backlight unit of claim 1, wherein:

each turning structure comprises a respective prism; and

each extraction feature is shallower than each prism.

6. The backlight unit of claim 1, wherein:

each extraction feature has a face oriented at an angle relative to the rear face; and

the first and second refractive indices are offset from the guide refractive index such that the front face has a total internal reflection angle greater than a total internal reflection angle of the rear face by at least twice the angle of the face of each extraction feature.

7. The backlight unit of claim 1, wherein each extraction feature is shaped such that the light encountering the respective extraction feature exits the light guide layer either by passing through the extraction feature or after reflection off of the extraction feature and subsequent reflection off of the front face.

8. The backlight unit of claim 1, wherein the second refractive index is offset from the guide refractive index such that the light encountering the front face after reflection off of the rear face or one of the extraction features does not pass through the front face.

9. The backlight unit of claim 1, wherein the plurality of turning structures are disposed in a turning film adhesively secured to the first cladding layer to form a solid film assembly with the light guide layer and the first and second cladding layers.

10. The backlight unit of claim 1, wherein the first and second cladding layers comprise first and second adhesive materials, respectively.

11. The backlight unit of claim 10, wherein the first and second adhesive materials have the first and second refractive indices, respectively.

12. The backlight unit of claim 10, wherein the second cladding layer comprises a plurality of diffusing structures suspended within the second adhesive material.

13. The backlight unit of claim 1, further comprising a concentrator disposed along an edge of the light guide layer into which the light is injected, the concentrator being configured such that the light undergoes total internal reflection from the front face until encountering at least one of the plurality of extraction features.

14. A display comprising:

a liquid crystal panel; and

a laminated backlight unit adhesively secured to the liquid crystal panel, the laminated backlight unit comprising;

a light guide layer comprising a plurality of extraction features disposed along a rear face of the light guide layer, each extraction feature having a face oriented at an angle relative to the rear face to cause light propagating through the light guide layer at a propagation angle within a predetermined range of angles to be extracted;

a first cladding layer adhered to the rear face of the light guide layer;

a plurality of turning structures disposed along the first cladding layer, the plurality of turning structures being configured to redirect the extracted light in a direction that corresponds with the propagation angle; and

a second cladding layer adhered to a front face of the light guide layer;

wherein the first cladding layer has a first refractive index lower than a guide refractive index of the light guide layer, and

wherein the second cladding layer has a second refractive index lower than the first refractive index such that the front face has a total internal reflection angle greater than a total internal reflection angle of the rear face by at least twice the angle of the face of each extraction feature.

15. The display of claim 14, wherein:

each extraction feature of the plurality of extraction features comprises a respective indentation in the rear face of the light guide layer;

the first cladding layer is composed of an adhesive material having the first refractive index; and

each indentation is filled with the adhesive material.

16. The display of claim 14, wherein:

each extraction feature has a face oriented at an angle relative to the rear face; and

the first and second refractive indices are offset from the guide refractive index such that the front face has a total internal reflection angle greater than a total internal reflection angle of the rear face by at least twice the angle of the face of each extraction feature.

17. The display of claim 14, wherein each extraction feature is shaped such that the light encountering the respective extraction feature exits the light guide layer either by passing through the extraction feature or after reflection off of the extraction feature and subsequent reflection off of the front face.

18. A backlight unit comprising:

a light guide layer into which light is injected, the light guide layer comprising a plurality of indentations, each indentation being disposed along a rear face of the light guide layer, each indentation being configured to cause the light to be extracted from the light guide layer as a result of the light encountering a respective one of the plurality of indentations, each indentation having a face oriented at an angle relative to the rear face;

a first cladding layer comprising a first adhesive material, the first cladding layer being secured to the rear face of the light guide layer via the first adhesive material, the first adhesive material having a first refractive index lower than a guide refractive index of the light guide layer, each indentation being filled with the first adhesive material;

a plurality of turning structures disposed along the first cladding layer; and

a second cladding layer comprising a second adhesive material, the second cladding layer being secured to a front face of the light guide layer via the second adhesive material, the second adhesive material having a second refractive index lower than the first refractive index;

wherein the first and second refractive indices are offset from the guide refractive index such that the front face has a total internal reflection angle greater than a total internal reflection angle of the rear face by at least twice the angle of the face of each indentation.

19. The backlight unit of claim 18, wherein each indentation is shaped such that the light encountering the respective indentation exits the light guide layer either by passing through the indentation or after reflection off of the indentation and subsequent reflection off of the front face.

20. The backlight unit of claim 18, further comprising a concentrator disposed along an edge of the light guide layer into which the light is injected, the concentrator being configured such that the light undergoes total internal reflection from the front face until encountering at least one of the plurality of indentations.