DIGITAL DISPLAY APPARATUS AND METHOD OF ASSEMBLING THE SAME

Abstract

A digital display apparatus and method of assembling the same is disclosed. The digital apparatus comprises a light source operable to emit light rays, and a rigid light transporter operable to transmit emitted light rays from the light source towards a viewing area. The digital display apparatus further comprises a flexible optical film operable to extract light rays transmitted through the rigid light transporter towards the viewing area, the flexible optical film further comprises at least one microstructure having a curvature, wherein the flexible optical film is adhered to a curved surface of the rigid light transporter, with a peak of the curvature of the at least one microstructure opposing the curved surface of the rigid light transporter.

Claims

1. A digital display apparatus for use in a motor vehicle, the digital display apparatus comprising: a light source operable to emit light rays; a rigid light transporter operable to transmit emitted light rays from the light source towards a viewing area; and a flexible optical film operable to extract light rays transmitted through the rigid light transporter towards the viewing area, the flexible optical film further comprising at least one microstructure having a curvature, wherein the flexible optical film is adhered to a curved surface of the rigid light transporter, with a peak of the curvature of the at least one microstructure opposing the curved surface of the rigid light transporter.

2. The digital display apparatus according to claim 1, wherein the flexible optical film has a total thickness ranging between 100 m to 400 m.

3. The digital display apparatus according to claim 1, wherein the at least one microstructure has a height ranging between 5 m to 100 m.

4. The digital display apparatus according to claim 1, wherein the at least one microstructure has a width ranging between 50 m to 100 m.

5. The digital display apparatus according to claim 1, further comprising an optically transparent adhesive deposited between the rigid light transporter and the flexible optical film.

6. The digital display apparatus according to claim 5, wherein the optically transparent adhesive, the rigid light transporter and the flexible optical film has a matching refractive index.

7. The digital display apparatus according to claim 1, wherein the viewing area has a size of at least 16 inches and has a curved form factor.

8. The digital display apparatus according to claim 1, wherein each of the at least one microstructure is systematically positioned on the flexible optical film relative to a position of the light source.

9. The digital display apparatus according to claim 8, wherein the flexible optical film comprises a lower count of the at least one microstructure positioned nearer to the position of the light source, and a higher count of the at least one microstructure positioned nearer to the position of the light source.

10. The digital display apparatus according to claim 1, wherein the rigid light transporter has a curved form factor, the curved form factor of the rigid light transporter approximately matching to the curved form factor of the viewing area.

11. A method of assembling a digital display apparatus, the method comprising: fabricating a mould for producing at least one flexible optical film comprising the steps of: laying a metal sheet for framing a flexible optical film on a flat plane; and producing, by way of lasering, at least one microstructure on the metal sheet, wherein the at least one microstructure lasered comprises a curvature.

12. The method according to claim 11, further comprising: producing at least one flexible optical film, by way of the mould fabricated, through an injection moulding process.

13. The method according to claim 12, further comprising: providing a rigid light transporter, the rigid light transporter having a curve radius ranging from preferably 0 mm to 4000 mm, more preferably 500 mm to 4000 mm, and even more preferably 1000 mm to 3000 mm.

14. The method according to claim 13, further comprising: depositing an optically transparent adhesive on a curved surface of the rigid light transporter; and adhering the at least one flexible optical film produced onto the curved surface of the rigid light transporter.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0035] Other objects and aspects of this disclosure will become apparent from the following description of embodiments with reference to the accompanying drawings in which:

[0036] FIG. 1A shows a cross-section view of an integrated light guide in accordance with an exemplary embodiment;

[0037] FIG. 1B shows a microstructure in accordance with an exemplary embodiment;

[0038] FIG. 2 shows a top view of a flexible optical film in accordance with an exemplary embodiment;

[0039] FIG. 3 shows a top view of a digital display apparatus in accordance with an exemplary embodiment;

[0040] FIG. 4 shows a side cross-section view of a digital display apparatus in accordance with an exemplary embodiment;

[0041] FIG. 5A shows flowchart 500a for fabricating a mould for producing a flexible optical film in accordance with an exemplary embodiment; and

[0042] FIG. 5B shows flowchart 500b for assembling a digital display apparatus having an integrated light guide in accordance with an exemplary embodiment.

[0043] In various embodiments described by reference to the above figures, like reference signs refer to like components in several perspective views and/or configurations.

DETAILED DESCRIPTION

[0044] The following detailed description is merely exemplary in nature and is not intended to limit the disclosure or the application and uses of the disclosure. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the disclosure or the following detailed description. It is the intent of this disclosure to present a digital display apparatus having an integrated light guide to achieve homogeneity. The integrated light guide includes a flexible optical film and a rigid light transporter, of which the integrated light guide is suitable for digital displays.

[0045] Hereinafter, the term transparent refers to an object or substance having transparent properties. Therefore, the term optically transparent adhesive refers to an adhesive having transparent properties, such that light rays are permitted to transmit through. In particular, when used as a means to adhere layers of optical elements together to produce an integrated, single optical element, incident light rays are transmitted through layers of optical elements or the integrated optical element. A type of optically transparent adhesive may be epoxy.

[0046] The term digital display used herein shall refer to electronic output device for presenting information in visual form. In the context of digital display within a motor vehicle, an example of a digital display includes a full digital dashboard (also known as digital cluster), and a hybrid digital dashboard. When used in the context herein, the term digital dashboard shall encompass both full digital dashboard and hybrid digital dashboard unless otherwise specified. The term digital dashboard shall refer to full digital instrument clusters which utilises digital display as an output apparatus for displaying vehicular information. The term hybrid dashboard shall encompass digital clusters which utilises a combination of analogue and digital electronic components, as a display apparatus for presenting vehicular information. Further, examples of digital display apparatus may include digital display apparatus having display layers fabricated using suitable digital display technologies. Example of digital display layers may include liquid crystal displays (LCD) organic light emitting diode (OLED) displays and thin film transistors (TFT) display layers.

[0047] The term curve refers to a line or an outline which gradually deviates from being a straight line, for at least a part of its length. Henceforth, the terms curve, curved, curvature, curve form and its variation thereof shall be taken to encompass line or outline as such, including convex and concave line or outline.

[0048] The term display radius refers to a display curvature or curve form factor of a display, which is measured in millimetres (mm) or denote by R.

[0049] Referring to FIG. 1A of the accompanying drawing, a side, cross-section view of an integrated light guide 100 in accordance with a preferred embodiment is shown. The integrated light guide 100 includes a rigid light transporter 102 and a flexible optical transporter 106. The rigid light transporter 102 is operable to transmit light rays through to a viewing area. The flexible optical transporter 106 comprises at least one microstructure 108, 108, 108, each of the at least one microstructure 108, 108, 108 having a curvature C (FIG. 1B referred). An example of a curvature profile may be a dome. With reference to FIG. 1B which shows an exemplary microstructure 108 in accordance with a preferred embodiment, the microstructure 108 has a height H ranging between 5 m to 100 m and a width W ranging between 50 m to 100 m. Turning back to FIG. 1A, the flexible optical film 106 is operable to extract light rays transmitted through the rigid light transporter 102 towards the viewing area 302, as shown in FIG. 3. The at least one microstructure 108, 108, 108 may be disposed on the flexible optical film 106 in a systematic manner.

[0050] Although FIG. 1A illustrates a flat panel integrated light guide 100, it shall not be limited thereto, and it shall be understood by a skilled practitioner the same inventive concept may be applied to produce integrated light guides in curved form. For example, the rigid light transporter 102 may have a curved form factor, such that light rays transmitted through to the viewing area 302 has a curved form factor as shown on FIG. 3, to implement an integrated light guide as disclosed herein, to a curved digital display apparatus. In some embodiments disclosed herein, the rigid light transporter has a curve radius ranging from preferably 0 mm to 4000 mm, more preferably 500-4000 mm, and even more preferably, 1000 mm to 3000 mm. In some embodiments disclosed herein, the rigid light transporter has a curve radius of infinity, , denoting a substantially flat surface or flat panel.

[0051] To produce an integrated light guide 100, an optically transparent adhesive 104 may be applied to a side of the rigid light transporter 102. If the rigid light transporter 102 has a curved form factor or in other words, a curved rigid light transporter 102 is used, the optically transparent adhesive 104 is applied to a convex surface of the rigid light transporter 102. Henceforth, the integrated light guide 100 produced includes a flexible optical film 106 having at least one microstructure 108, 108 and 108 systematically positioned, each of the microstructure 108, 108, 108 having a curvature C, with a peak P of the curvature C of the at least one microstructure 108, 108, 108 opposing the curved surface of the rigid light transporter 102. Preferably, the optically transparent adhesive 104, the rigid light transporter 102 and the flexible optical film 106 has a matching refractive index, such that light rays may be transmitting though the integrated light guide 100.

[0052] FIG. 2 shows a top view of a flexible optical film 106 in accordance with an exemplary embodiment. As can be seen from FIG. 2, at least one microstructure 108, 108, 108 is systematically positioned on a surface of the flexible optical film 106. Each of the at least one microstructure 108, 108, 108 has a curvature profile or a dome-like microstructure with a peak P. Preferably, the flexible optical film 106 has a total thickness ranging between 100 m to 400 m. The flexible optical film 106 may be polish, ed to produce a mirror polished surface quality. In this exemplary embodiment, the at least one microstructure 108, 108, 108 are positioned such that one side of the flexible optical film 106 has a plurality of microstructures 108, 108, 108 sparsely scattered on the flexible optical film while the other end of the flexible optical film 106 a plurality of microstructures 108, 108, 108 are densely scattered. The aforesaid configuration is suitable for edge-lit digital displays where the flexible optical film 106 has a lower count of the at least one microstructure positioned nearer to a position of a light source, i.e., microstructures are sparsely scattered, and a higher count of the at least one microstructure positioned nearer to the position of the light source, i.e., microstructures are densely scattered.

[0053] A main advantage of the flexible optical film 106 as disclosed herein is the total thickness of the flexible optical film 106 ranges between 100 m to 400 m, thus yielding thin integrated light guide, therefore a total thickness of digital display apparatus is also reduced. Another advantage of the flexible optical film 106 disclosed is that shape accuracy, i.e., curvature of each of the at least one microstructure 108, 108, 108 may be produced, as a result of the flexible optical film 106 being produced on a flat panel in contrast with moulding microstructure directly on the light guide itself. Yet another advantage is that the flexible optical film 106 may be applied on curved rigid light transporter of any radius or curve form factor. Naturally, the microstructures 108, 108, 108 orientates to a curve surface of the rigid light transporter, reducing distortion of the microstructures 108, 108, 108.

[0054] FIG. 3 shows a top view of a digital display apparatus 300 in accordance with an exemplary embodiment. In this exemplary embodiment, the digital display apparatus 300 is a large size, curved display apparatus, with a viewing area 302. The viewing area 302 is operable to display content or information. Preferably, the viewing area has a size of at least 16 inches and has a curved form factor. In this exemplary embodiment, the rigid light transporter 102 has a curved form factor, the curved form factor of the rigid light transporter 102 approximately matching to the curved form factor of the viewing area 302. The digital display apparatus 300 includes an integrated light guide 100. As can be seen from FIG. 3, the flexible optical film 106 is positioned furthest away from the viewing area 3002, or backward of the rigid light transporter 102. Preferably, the rigid light transporter has a curved form factor, the curved form factor of the rigid light transporter 102 approximately matching to the curved form factor of the viewing area.

[0055] FIG. 4 shows a side cross-section view of a digital display apparatus 400 in accordance with an exemplary embodiment. The digital display apparatus 400 includes an Illumination source 402 operable to emit light rays, an integrated light guide 100 comprising a rigid light transporter 106 to transmit light rays emitted from the illumination source 402. In this exemplary embodiment, the illumination source 402 is arranged on an edge of the digital display 400. The integrated light guide 100 further comprises a flexible optical film 106 operable to extract light rays transmitted through the rigid light transporter towards the viewing area, the flexible optical film 106 further comprises at least one microstructure having a curvature C.

[0056] Optionally, an optical film diffusor 404 may be placed forward of the rigid light guide 102. Optionally, the optical elements are placed within a housing of a digital display apparatus, applied with reflector foil 406, 406 to optimise reflection of light rays within an ambient of a digital display apparatus 400, to be extracted by the flexible optical film 106 and transmitted through the rigid light transporter 102, towards a viewing area.

[0057] In an exemplary embodiment, a master mould may be fabricated, for producing the flexible optical film 106 and producing an integrated light guide 100 as disclosed herein.

[0058] FIG. 5A shows flowchart 500a for fabricating a mould for producing the flexible optical film 106. At step 502, a metal sheet is laid on a flat plane. At a next step 504, lasering is applied to the metal sheet to produce at least one microstructure 108, 108 or 108, the microstructure 108, 108 or 108 having a curvature C. Consequently, a master mould is produced. At step 506, at least one flexible optical film 106 may be produced using the master mould fabricated from steps 502 and 504, by applying injection moulding process.

[0059] Referring now to FIG. 5B which shows flowchart 500b for assembling a digital display apparatus 300, 400, at a step 508, a rigid light transporter for transmitting light rays through the digital display apparatus 300, 400 to a viewing area is provided. In a preferred embodiment, the rigid light transporter may be a flat panel, for producing a flat panel digital display apparatus. In a preferred embodiment, the rigid light transporter possesses a curved form factor or a display radius, for producing a curved display apparatus.

[0060] At step 510, an optically transparent adhesive is applied or deposited on the rigid light transporter. In a preferred embodiment where the rigid light transporter has a curved form factor, the optically transparent adhesive is applied or deposited on a curved side of the rigid light transporter. At step 512, the at least one optical film produced is adhered to a side of the rigid light transporter. More specifically, the at least one optical film produced is adhered to a curved side of the rigid light transporter, thereby producing an integrated light guide for assembling a digital display apparatus.

[0061] A known method of producing conical shaped optical elements within layers of displays is to apply lasering techniques directly on a light guide such that the conical-shaped optical elements are produced on the light guide itself. However, if the display is a curved display and a curved light guide is used, the resultant conical shaped optical elements produced may be inconsistent, with distortion of cavities and lens on the light guide element. A main advantage of producing a master mould for fabricating a flexible optical film to be adhered to a rigid light transporter aims to ameliorate the aforesaid problem.

[0062] Thus, it can be seen that a large, curved digital display apparatus having an integrated light guide which achieves homogeneity has been provided. In particular, the integrated light guide is produced using a combination a flexible optical film and a rigid light transporter. In addition, the flexible optical film includes at least one microstructure with a curvature to extract light rays which passes through to the rigid light guide for transmitting light rays towards the viewing area of the large, curved digital display apparatus, thereby optimizing light rays being transmitted through to the viewing area. Further thereto, in contrast with conventional method which apply lasering method directly to a curved light transporter to produce structures for extracting light rays to achieve homogeneity, which may result in distorted structures due to fabricating of structures on a curved surface, the present disclosure proposes to at least ameliorate the problems as discussed above by using a flexible optical film that may be adhered to a rigid light transporter. While exemplary embodiments have been presented in the foregoing detailed description of the disclosure, it should be appreciated that a vast number of variation exist.

[0063] It should further be appreciated that the exemplary embodiments are only examples, and are not intended to limit the scope, applicability, operation or configuration of the disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the disclosure, it being understood that various changes may be made in the function and arrangement of elements and method of operation described in the exemplary embodiment without departing from the scope of the disclosure as set forth in the appended claims.