What is claimed is:
1. A process for manufacturing a light diffusing structure, comprising the step of directing collimated or nearly-collimated light through a transparent or translucent substrate and into a layer of photopolymerizable material for a period of time sufficient to photopolymerize only a portion of the photopolymerizable material.
2. A process as set forth in claim 1, further comprising the step of selecting the substrate from a material from one or more of the classes of (a) amorphous materials; (b) semi-crystalline materials that contain crystalline domains interspersed in an amorphous matrix; and (c) purely crystalline materials.
3. A process as set forth in claim 1, further comprising the step of fabricating the photopolymerizable material from at least one photopolymerizable monomer or oligomer.
4. A process as set forth in claim 1, further comprising the step of fabricating the photopolymerizable material from at least one photopolymerizable monomer or oligomer, and a photoinhibitor.
5. A process as set forth in claim 1, further comprising the step of placing the layer of photopolymerizable material on the substrate.
6. A process as set forth in claim 1, further comprising the step of generating light having a divergence angle of less than ten degrees.
7. A process as set forth in claim 1, further comprising the step of directing the light through the substrate in more than one dose.
8. A process as set forth in claim 1, further comprising the step of removing the unphotopolymerized portion of the photopolymerizable material.
9. A process as set forth in claim 1, further comprising the step of removing the photopolymerized portion of the photopolymerizable material from the substrate.
10. A process as set forth in claim 1, further comprising the steps of:
removing the unphotopolymerized portion of the photopolymerizable material; and
placing transparent or translucent fill material on the surface of the photopolymerized photopolymerizable material.
11. A process as set forth in claim 10, where the step of placing transparent or translucent fill material on the surface of the photopolymerized photopolymerizable material comprises the step of selecting a fill material having an index of refraction less than that of the photopolymerizable material.
12. A process as set forth in claim 10, further comprising the step of placing light-scattering particles in the fill material.
13. A process as set forth in claim 1, further comprising the step of combining the photopolymerized photopolymerizable material with an array of tapered optical waveguides, each tapered optical waveguide comprising:
an input surface that admits light;
an output surface distal from the input surface, the output surface having a surface area less than that of the input surface; and
a sidewall or sidewalls disposed between the input and output surfaces for effecting total reflection of the light rays received by the input surface.
14. A process as set forth in claim 13, where the step of combining the photopolymerized photopolymerizable material with an array of tapered optical waveguides comprises the step of placing the photopolymerized photopolymerizable material in juxtaposition to the input or the output surface of the tapered optical waveguides.
15. A process as set forth in claim 13, where the tapered optical waveguides are lenticular.
16. A process as set forth in claim 1, further comprising the steps of:
removing the unphotopolymerized portion of the photopolymerizable material;
forming a metallic layer on the surface of the photopolymerized photopolymerizable material to form a conforming replica layer; and
applying the metallic replica layer to embossable material.
17. A process as set forth in claim 16, further comprising the step of placing light-scattering particles in the embossable material.
18. A process as set forth in claim 16, further comprising the step of combining the embossable material to which the metallic replica layer has been applied with an array of tapered optical waveguides, each tapered optical waveguide comprising:
an input surface that admits light;
an output surface distal from the input surface, the output surface having a surface area less than that of the input surface; and
a sidewall or sidewalls disposed between the input and output surfaces for effecting total reflection of the light rays received by the input surface.
19. A process as set forth in claim 18, where the step of combining the embossable material with an array of tapered optical waveguides comprises the step of placing the photopolymerized photopolymerizable material in juxtaposition to the input or the output surface of the tapered optical waveguides.
20. A process as set forth in claim 18, where the tapered optical waveguides are lenticular.
21. A process for manufacturing a light diffusing structure, comprising the steps of:
selecting a transparent or translucent substrate from a material from one or more of the classes of (a) amorphous materials; (b) semi-crystalline materials that contain crystalline domains interspersed in an amorphous matrix; and (c) purely crystalline materials, the substrate having first and second surfaces generally flat and parallel to each other;
depositing a layer of photopolymerizable material comprising at least one photopolymerizable monomer or oligomer, and a photoinhibitor, on the first surface of the substrate;
directing collimated or nearly-collimated light through the second surface of the substrate and into the photopolymerizable material for a period of time sufficient to photopolymerize only a portion of the photopolymerizable material; and
removing the unphotopolymerized portion of the photopolymerizable material.
22. An apparatus for manufacturing a light diffusing structure, comprising:
a transparent or translucent substrate;
a layer of photopolymerizable material; and
means for directing collimated or nearly-collimated light through the substrate and into the photopolymerizable material for a period of time sufficient to photopolymerize only a portion of the photopolymerizable material.
23. An apparatus as set forth in claim 22, where the substrate is fabricated from a material from one or more of the classes of (a) amorphous materials; (b) semi-crystalline materials that contain crystalline domains interspersed in an amorphous matrix; and (c) purely crystalline materials.
24. An apparatus as set forth in claim 22, where the photopolymerizable material is fabricated from at least one photopolymerizable monomer or oligomer.
25. An apparatus as set forth in claim 22, where the photopolymerizable material is fabricated from at least one photopolymerizable monomer or oligomer, and a photoinhibitor.
26. An apparatus as set forth in claim 22, where the layer of photopolymerizable material is on the substrate.
27. An apparatus as set forth in claim 22, where the means for directing light generates light having a divergence angle of less than ten degrees.
28. An apparatus as set forth in claim 22, where the means for directing light directs the light through the substrate in more than one dose.
29. An apparatus as set forth in claim 22, further comprising means for removing the unphotopolymerized portion of the photopolymerizable material.
30. An apparatus as set forth in claim 22, further comprising means for removing the photopolymerized portion of the photopolymerizable material from the substrate.
31. An apparatus as set forth in claim 22, further comprising a transparent or translucent fill material on the surface of the photopolymerized photopolymerizable material.
32. An apparatus as set forth in claim 31, where the fill material has an index of refraction less than that of the photopolymerizable material.
33. An apparatus as set forth in claim 31, where the fill material contains light-scattering particles.
34. An apparatus as set forth in claim 22, further comprising an array of tapered optical waveguides, each tapered optical waveguide comprising:
an input surface that admits light;
an output surface distal from the input surface, the output surface having a surface area less than that of the input surface; and
a sidewall or sidewalls disposed between the input and output surfaces for effecting total reflection of the light rays received by the input surface.
35. An apparatus as set forth in claim 34, where the photopolymerized photopolymerizable material is in juxtaposition to the input or the output surface of the tapered optical waveguides.
36. An apparatus as set forth in claim 34, where the tapered optical waveguides are lenticular.
37. An apparatus as set forth in claim 22, further comprising:
means for removing the unphotopolymerized portion of the photopolymerizable material;
means for forming a metallic layer on the surface of the photopolymerized photopolymerizable material to form a conforming replica layer; and
means for applying the metallic replica layer to embossable material.
38. An apparatus as set forth in claim 37, where the embossable material contains light-scattering particles.
39. An apparatus as set forth in claim 37, further comprising an array of tapered optical waveguides, each tapered optical waveguide comprising:
an input surface that admits light;
an output surface distal from the input surface, the output surface having a surface area less than that of the input surface; and
a sidewall or sidewalls disposed between the input and output surfaces for effecting total reflection of the light rays received by the input surface.
40. An apparatus as set forth in claim 39, where the photopolymerized photopolymerizable material is in juxtaposition to the input or the output surface of the tapered optical waveguides.
41. An apparatus as set forth in claim 39, where the tapered optical waveguides are lenticular.
42. An apparatus for manufacturing a light diffusing structure, comprising:
a transparent or translucent substrate fabricated from a material from one or more of the classes of (a) amorphous materials; (b) semi-crystalline materials that contain crystalline domains interspersed in an amorphous matrix; and (c) purely crystalline materials, the substrate having first and second surfaces generally flat and parallel to each other;
a layer of photopolymerizable material, comprising at least one photopolymerizable monomer or oligomer, and a photoinhibitor, deposited on the first surface of the substrate;
a light source for directing collimated or nearly-collimated light through the second surface of the substrate and into the photopolymerizable material for a period of time sufficient to photopolymerize only a portion of the photopolymerizable material; and
means for removing the unphotopolymerized portion of the photopolymerizable material.
43. An optical diffuser comprising photopolymerizable material exposed to a source of collimated or nearly-collimated light first directed through a transparent or translucent substrate for a period of time sufficient to photopolymerize only a portion of the photopolymerizable material.
44. An optical diffuser as set forth in claim 43, where the substrate is fabricated from a material from one or more of the classes of (a) amorphous materials; (b) semi-crystalline materials that contain crystalline domains interspersed in an amorphous matrix; and (c) purely crystalline materials.
45. An optical diffuser as set forth in claim 43, where the photopolymerizable material is fabricated from at least one photopolymerizable monomer or oligomer.
46. An optical diffuser as set forth in claim 43, where the photopolymerizable material is fabricated from at least one photopolymerizable monomer or oligomer, and a photoinhibitor.
47. An optical diffuser as set forth in claim 43, where the photopolymerizable material is on the substrate.
48. An optical diffuser as set forth in claim 43, where the light has a divergence angle of less than ten degrees.
49. An optical diffuser as set forth in claim 43, where the light is directed through the substrate in more than one dose.
50. An optical diffuser as set forth in claim 43, further comprising a layer of transparent or translucent fill material on the surface of the photopolymerized photopolymerizable material.
51. An optical diffuser as set forth in claim 50, where the fill material has an index of refraction less than that of the photopolymerizable material.
52. An optical diffuser as set forth in claim 50, where the fill material contains light-scattering particles.
53. An optical diffuser as set forth in claim 43, further comprising an array of tapered optical waveguides, each tapered optical waveguide comprising:
an input surface that admits light;
an output surface distal from the input surface, the output surface having a surface area less than that of the input surface; and
a sidewall or sidewalls disposed between the input and output surfaces for effecting total reflection of the light rays received by the input surface.
54. An optical diffuser as set forth in claim 53, where the photopolymerized photopolymerizable material is in juxtaposition to the input or the output surface of the tapered optical waveguides.
55. An optical diffuser as set forth in claim 53, where the tapered optical waveguides are lenticular.
56. An optical diffuser comprising photopolymerizable material, comprising at least one photopolymerizable monomer or oligomer, and a photoinhibitor, exposed to a source of collimated or nearly-collimated light first directed through a transparent or translucent substrate, the substrate being fabricated from a material from one or more of the classes of (a) amorphous materials; (b) semi-crystalline materials that contain crystalline domains interspersed in an amorphous matrix; and (c) purely crystalline materials, for a period of time sufficient to photopolymerize only a portion of the photopolymerizable material.
57. An apparatus for manufacturing a light diffusing structure, comprising a metallic layer formed on a layer of photopolymerizable material exposed to a source of collimated or nearly-collimated light first directed through a transparent or translucent substrate for a period of time sufficient to photopolymerize only a portion of the photopolymerizable material after the unphotopolymerized portion of the photopolymerizable portion has been removed.
58. An apparatus as set forth in claim 57, where the substrate is fabricated from a material from one or more of the classes of (a) amorphous materials; (b) semi-crystalline materials that contain crystalline domains interspersed in an amorphous matrix; and (c) purely crystalline materials.
59. An apparatus as set forth in claim 57, where the photopolymerizable material is fabricated from at least one photopolymerizable monomer or oligomer.
60. An apparatus as set forth in claim 57, where the photopolymerizable material is fabricated from at least one photopolymerizable monomer or oligomer, and a photoinhibitor.
61. An apparatus as set forth in claim 57, where the photopolymerizable material is on the substrate.
62. An apparatus as set forth in claim 57, where the light source generates light having a divergence angle of less than ten degrees.
63. An apparatus as set forth in claim 57, where the light source generates light in more than one dose.
64. A mold for manufacturing a light diffusing structure, comprising a metallic layer formed on a layer of photopolymerizable material, comprising at least one photopolymerizable monomer or oligomer, and a photoinhibitor, exposed to a source of collimated or nearly-collimated light first directed through a transparent or translucent substrate, the substrate being fabricated from a material from one or more of the classes of (a) amorphous materials; (b) semi-crystalline materials that contain crystalline domains interspersed in an amorphous matrix; and (c) purely crystalline materials, for a period of time sufficient to photopolymerize only a portion of the photopolymerizable material after the unphotopolymerized portion of the photopolymerizable portion has been removed.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A light source assembly comprising:
a substrate extending in a first direction; and
a plurality of light source parts arranged in the first direction, each of which comprising:
a light source which is on the substrate and generates light;
a first reflecting element on the substrate, and a first opening which is defined in the first reflecting element and exposes the light source;
a second reflecting element on the first reflecting element, and a second opening which is defined in the second reflecting element and exposes the light source, wherein the second reflecting element is smaller than the first reflecting element in a plan view; and
a lens which is on the light source and the second reflecting element, and diffuses the light from the light source.
2. The light source assembly of claim 1, wherein
the first reflecting element comprises a material configured to cause mirror reflection of light, and the second reflecting element comprises a material configured to cause diffuse reflection of light, or
the first reflecting element comprises the material configured to cause diffuse reflection of light, and the second reflecting element comprises the material configured to cause mirror reflection of light.
3. The light source assembly of claim 2, wherein
the material configured to cause mirror reflection of light comprises silver or aluminum, and
the material configured to cause diffuse reflection of light comprises polyethylene phthalate and has a white color.
4. The light source assembly of claim 2, wherein
each of the first and second reflecting elements has a circular sheet shape,
the lens has a hemisphere shape,
an external diameter of the first reflecting element is more than about 100% and less than about 130% of an external diameter of the lens, in the plan view, and
an external diameter of the second reflecting element is more than about 70% and less than 100% of the external diameter of the lens, in the plan view.
5. The light source assembly of claim 2, further comprising a marker which is disposed on the substrate and indicates a position of the lens relative to the light source on the substrate.
6. The light source assembly of claim 5, wherein the lens comprises:
a top surface having a dome shape, a bottom surface opposite to the top surface, and a fixing part protruded from the bottom surface, and
the fixing part is attached on the substrate and contacts the marker on the substrate.
7. The light source assembly of claim 6, wherein
the lens further comprises a fixing protrusion protruded from the fixing portion,
the marker is a fixing hole defined through the substrate, and
the fixing protrusion is in the fixing hole.
8. The light source assembly of claim 6, wherein
the marker on the substrate comprises three discrete points corresponding to vertexes of a triangle which has a center at the light source, and
the fixing portion of the lens corresponds to the three discrete points.
9. The light source assembly of claim 8, wherein the first opening of the first reflecting element is larger than the second opening of the second reflecting element.
10. A light source assembly comprising:
a substrate extending in a first direction; and
a plurality of light source parts arranged in the first direction, each of which comprising:
a light source which is on the substrate and generates light;
a first reflecting element on the substrate and comprising:
a first area, and a second area adjacent to the first area, and
a plurality of beads which is in the second area and diffuses the light in the second area;
a first opening which is defined in the first reflecting element and exposes the light source; and
a lens which is on the light source and the first reflecting element, and diffuses the light.
11. The light source assembly of claim 10, wherein
the first reflecting element comprises a material configured to cause diffuse reflection of light, and the first area is adjacent to the light source and between the light source and the second area in a plan view, or
the first reflecting element comprises a material configured to cause mirror reflection of light, and the second area is adjacent to the light source and between the light source and the first area in the plan view.
12. A display apparatus comprising:
a liquid crystal display panel which displays an image;
a light source assembly which generates and supplies light to the liquid crystal display panel, and is under the liquid crystal display panel;
a reflecting sheet between the liquid crystal display panel and the light source assembly, and a plurality of lens openings defined in the reflecting sheet; and
a receiving container which receives the liquid crystal display panel, the light source assembly and the reflecting sheet, and comprises a bottom portion, and side walls extending from the bottom portion substantially perpendicular to the bottom portion,
wherein the light source assembly comprises:
a substrate which extends in a first direction and is on the bottom portion of the receiving container; and
a plurality of light source parts arranged in the first direction, each of which comprising:
a light source which is on the substrate and generates the light;
a first reflecting element on the substrate, and a first opening which is defined in the first reflecting element and exposes the light source;
a second reflecting element which is on the first reflecting element, and a second opening which is defined in the second reflecting element and exposes the light source, wherein the second reflecting element is smaller than the first reflecting element in a plan view; and
a lens which is on the light source and the second reflecting element, and diffuses the light from the light source, and
wherein the lens openings of the reflecting sheet respectively correspond to the light source parts of the light source assembly.
13. The display apparatus of claim 12, wherein
the first reflecting element comprises a material configured to cause mirror reflection of light, and the second reflecting element comprises a material configured to cause diffuse reflection of light, or
the first reflecting element comprises the material configured to cause diffuse reflection of light, and the second reflecting element comprises the material configured to cause mirror reflection of light.
14. The display apparatus of claim 13, wherein a portion of the corresponding lens of the light source part of the light source assembly is above a corresponding lens opening of the reflecting sheet.
15. The display apparatus of claim 14, wherein in the plan view, the lens opening of the reflecting sheet is larger than the lens of the light source part of the light source assembly, and is smaller than the first reflecting element of the light source part of the light source assembly
16. The display apparatus of claim 12, further comprising a plurality of light source assemblies on the bottom portion of the receiving container, wherein the light source assemblies are arranged in a second direction which is perpendicular to the first direction.
17. A method of manufacturing a display apparatus comprising:
forming a light source assembly;
disposing the light source assembly on a bottom portion of a receiving container; and
disposing a display panel in the receiving container,
wherein the forming the light source assembly comprises forming a light source part formed by:
mounting a light emitting diode chip on a substrate which extends in a first direction, by a surface mounting technology;
forming a first reflecting element in which a first opening is defined and exposes the light emitting diode chip, on the substrate having the light emitting diode chip thereon;
forming a second reflecting element in which a second opening is defined and exposes the light emitting diode chip, the second reflecting element being smaller than the first reflecting element, in a plan view; and
forming a lens on the substrate having the light emitting diode chip and the first and second reflecting elements thereon;
wherein
the first reflecting element comprises a material configured to cause mirror reflection of light, and the second reflecting element comprises a material configured to cause diffuse reflection of light, or
the first reflecting element comprises the material configured to cause diffuse reflection of light, and the second reflecting element comprises the material configured to cause mirror reflection of light.
18. The method of claim 17, further comprising attaching a reflecting sheet on the light source assembly, after the disposing the light source assembly,
wherein
the forming the light source assembly further comprises forming a plurality of light source parts, and
a plurality of lens openings defined in the reflecting sheet corresponds to the plurality of the light source parts.
19. The method of claim 17, wherein the forming the light source assembly further comprises:
forming a marker adjacent to a position for the light emitting diode chip on the substrate, before the mounting the light emitting diode chip,
wherein the marker indicates the position for the light emitting diode chip on the substrate.
20. The method of claim 19,
wherein the lens comprises a top surface having a dome shape, a bottom surface opposite to the top surface, and a fixing portion protruded from the bottom surface, and
wherein the forming the lens comprises attaching the fixing portion to the marker on the substrate, to fix the lens on the substrate relative to the position for the light emitting diode chip.