Light distribution structure and element, related method and uses
A method for manufacturing a light distribution structure in the form of an optically functional layer includes at least one three-dimensional feature pattern established in a light-transmitting carrier by a plurality of three-dimensional optical features. The method also includes manufacturing a patterned master tool for the at least one three-dimensional feature pattern by a piezoelectric cutting method selected from a fast tool servo method and a stylus engraving method, or by a laser engraving method, and transferring the at least one three-dimensional feature pattern onto the light-transmitting carrier.
1. A method for manufacturing a light distribution structure in the form of an optically functional layer comprising at least one three-dimensional feature pattern formed in a light-transmitting carrier by a plurality of three-dimensional optical features, the method comprising:
providing a patterned master tool that has a tool pattern corresponding to the at least one three-dimensional feature pattern, wherein the tool pattern is formed by a fast tool servo process or a stylus engraving process, or by a laser engraving process, and
transferring a profile of the tool pattern onto the light-transmitting carrier to form the at least one three-dimensional feature pattern; and
wherein the at least one three-dimensional feature pattern is established in a light-transmitting carrier medium by a plurality of internal optical cavities,
wherein each of the plurality of internal optical cavities is configured to establish at least one optical function at a horizontal surface and at an inclined surface, the plurality of internal optical cavities being arranged in a direction along an essentially longitudinal light propagation path in the light-transmitting carrier medium,
wherein by the horizontal surface an optical cavity is configured to mediate light propagation in the light-transmitting carrier medium along the essentially longitudinal light propagation path, and to further distribute light rays reflected from the horizontal surface, in the light-transmitting carrier medium, towards the inclined surface of a subsequent optical cavity of the plurality of internal optical cavities via a plurality of light passage areas,
wherein by the inclined surface the optical cavity is configured to extract light out of the light distribution structure in a predetermined direction essentially transverse to the longitudinal light propagation path, and
wherein an edge of the inclined surface of each optical cavity has a curved shape or a wave-shape as viewed along a normal to the horizontal surface.
2. The method of claim 1 ,
wherein the plurality of three-dimensional optical features is variable in terms of at least one of a cross-sectional profile, dimensions, periodicity, orientation, and disposition thereof within the at least one three-dimensional feature pattern.
3. The method of claim 1 ,
wherein the patterned master tool is planar or cylindrical.
4. The method of claim 1 ,
wherein the transferring the profile of the tool pattern onto the light-transmitting carrier to form the at least one three-dimensional feature pattern is implemented by a roll-to-roll method, a roll-to-sheet method, or a sheet-to-sheet method.
5. The method of claim 1 , further comprising:
a surface polishing treatment.
6. A method for manufacturing a light distribution structure in the form of an optically functional layer comprising at least one three-dimensional feature pattern formed in a light-transmitting carrier by a plurality of three-dimensional optical features, the method comprising:
providing a patterned master tool that has a tool pattern corresponding to the at least one three-dimensional feature pattern, wherein the tool pattern is formed by a fast tool process or a stylus engraving process or by a laser engraving process, and
transferring a profile of the tool pattern onto the light-transmitting carrier to form the at least one three-dimensional feature pattern; and
wherein the tool pattern is provided as symmetrical or asymmetrical sinusoidal waveforms.
7. The method of claim 6 ,
wherein the plurality of three-dimensional optical features is variable in terms of at least one of a cross-sectional profile, dimensions, periodicity, orientation, and disposition thereof within the at least one three-dimensional feature pattern.
8. The method of claim 6 ,
wherein the patterned master tool is planar or cylindrical.
9. The method of claim 6 ,
wherein the transferring the profile of the tool onto the light-transmitting carrier to form the at least one three-dimensional feature pattern is implemented by a roll-to-roll method, a roll-to-sheet method, or a sheet-to-sheet method.
10. The method of claim 6 , further comprising:
a surface polishing treatment.