Manufacturing method of near-to-eye display device and near-to-eye display device
Through mold forming technology, melted light-transmitting materials are directly injected and press-synthetic molded, which solves the problems of waste and high cost of materials in the production of near-eye display equipment, and achieves a more efficient production process.
Patent Information
- Application Number
- CN202311245604.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-09-25
- Publication Date
- 2025-03-28
AI Technical Summary
There are problems of waste of materials and high production costs in the production process of existing near-eye display equipment, and the processing steps are complex.
By adopting mold forming technology, by injecting molten light-transmissive material between the first mold and the second mold, pressing the material to bond with the inner wall of the mold, cooling and curing, demolding, forming an optical matrix, reducing material cutting and processing steps.
It reduces waste of raw materials, reduces production costs, simplifies processing steps, and improves production efficiency.
Smart Images
Figure CN119704735A_ABST
Abstract
Description
Technical Field
[0001] The present application belongs to the field of augmented reality display technology, and more specifically, to a method for manufacturing a near-eye display device and a near-eye display device. Background Art
[0002] AR augmented reality devices generally include a micro display and an optical module. The micro display is used to provide display content. For the optical module, the mainstream AR display technology currently uses waveguide technology. The waveguide couples the light projected by the micro display into its own glass substrate, and transmits the light coupling like a transmission channel to the front of the eye through the principle of "total reflection", and then releases the light into the human eye through the decoupling part. Of course, there is also PRISM technology, which uses a prism to directly reflect the light from the micro display into the human eye. At the same time, external light can also enter the human eye from the outside through the prism.
[0003] The inventors of the present application have discovered that existing near-eye display devices generally use a cutting process to form an optical module, but the above method is likely to cause waste of raw materials, greatly increasing the production cost of the near-eye display device; in addition, in the subsequent processing process, each step requires a separate process, the steps are often too complicated, and the time and money costs consumed are high. Summary of the invention
[0004] The embodiments of the present application provide a method for manufacturing a near-eye display device and a near-eye display device.
[0005] In a first aspect, an embodiment of the present application provides a method for manufacturing a near-eye display device, comprising:
[0006] A first mold is provided, the first mold comprising a first accommodating cavity and a second accommodating cavity which are spaced apart from each other, the inner wall of the first accommodating cavity is provided with a first plane and a convex surface, the first plane is arranged around the convex surface, the second accommodating cavity is provided with a second plane and an annular surface, the annular surface is arranged around the second plane;
[0007] Providing a second mold, the second mold is located on a side of the first mold facing the first accommodating cavity and the second accommodating cavity;
[0008] Injecting molten light-transmitting material between the first mold and the second mold to fill the first accommodating cavity and the second accommodating cavity;
[0009] Pressing the first mold and the second mold together so that the molten light-transmitting material is fully in contact with the first plane and the convex surface, the second plane and the annular surface;
[0010] After the molten light-transmitting material is cooled and solidified, the first mold and the second mold are demolded to obtain the first optical matrix and the second optical matrix formed after the molten light-transmitting material is solidified, wherein the structure of the first optical matrix corresponds to the first plane and the convex surface, and the structure of the second optical matrix corresponds to the second plane and the annular surface.
[0011] In a second aspect, an embodiment of the present application provides a near-eye display device, which is manufactured by any one of the manufacturing methods of the first aspect above.
[0012] The method comprises providing a first mold including a first accommodating cavity and a second accommodating cavity arranged at intervals, wherein the inner wall of the first accommodating cavity is provided with a first plane and a convex surface, the first plane is arranged around the convex surface, and the second accommodating cavity is provided with a second plane and an annular surface, and the annular surface is arranged around the second plane; providing a second mold, the second mold being located on the side of the first mold facing the first accommodating cavity and the second accommodating cavity; injecting molten light-transmitting material between the first mold and the second mold to fill the first accommodating cavity and the second accommodating cavity; pressing the first mold and the second mold so that the molten light-transmitting material fully fits with the first plane and the convex surface, the second plane and the annular surface; demolding the first mold and the second mold after the molten light-transmitting material is cooled and solidified, and obtaining the first optical matrix and the second optical matrix formed after the molten light-transmitting material is solidified, wherein the structure of the first optical matrix corresponds to the first plane and the convex surface, and the structure of the second optical matrix corresponds to the second plane and the annular surface. The above method does not need to cut the mirror body material, reduces the loss of raw materials, and greatly reduces the production cost. In addition, a variety of different design surfaces are directly formed on one side of a mold, which can reduce the number of molds, and can also reduce the operation steps and time of subsequent processes, greatly reducing the cost.
[0013] Other aspects and advantages of the embodiments of the present disclosure will be set forth in part in the following description, or may be learned from the description, or may be learned through practice of the embodiments. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.
[0015] Figure 1 A schematic diagram of a process flow of an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0016] Figure 2 A schematic diagram of a mold structure of an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0017] Figure 3 A schematic diagram of a mold structure of another embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0018] Figure 4 A schematic structural diagram of mold pressing of an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0019] Figure 5 A schematic diagram of the optical substrate structure after demoulding according to an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0020] Figure 6 A schematic diagram of the upward-looking structure of the mirror body after demoulding according to an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0021] Figure 7 A schematic diagram of the upward-looking structure of the mirror body after demoulding according to another embodiment of the method for manufacturing the near-eye display device provided in an embodiment of the present application;
[0022] Figure 8 A schematic diagram of a coating structure of an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0023] Fig. 9 A schematic diagram of the structure of installing a micro display according to an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0024] Fig.10 A schematic diagram of the structure of cutting of an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0025] Fig.11 A schematic diagram of the structure of the package of an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0026] Fig.12 A schematic diagram of the structure of the package of an embodiment of a method for manufacturing a near-eye display device provided in an embodiment of the present application;
[0027] Fig.13 A schematic structural diagram of an embodiment of a near-eye display device provided in an embodiment of the present application. DETAILED DESCRIPTION
[0028] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present application more clearly understood, the present application is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.
[0029] It should be noted that when an element is referred to as being "fixed to" or "disposed on" another element, it can be directly on the other element or indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element.
[0030] It should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.
[0031] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.
[0032] The manufacturing method of the near-eye display device provided in the embodiment of the present application is now described.
[0033] refer to Figure 1-13 , a method for manufacturing a near-eye display device comprises:
[0034] S11, providing a first mold 200, the first mold 200 comprising a first accommodating cavity 410 and a second accommodating cavity 420 which are arranged at intervals, the inner wall of the first accommodating cavity 410 is provided with a first plane 310 and a convex surface 320, the first plane 310 is arranged around the convex surface 320, the second accommodating cavity 420 is provided with a second plane 330 and an annular surface 340, the annular surface 340 is arranged around the second plane 330;
[0035] In some embodiments, the first accommodating cavity 410 and the second accommodating cavity 420 provided in the first mold 200 include at least one group, which can also be arranged in a straight line or array, etc. The lateral dimensions of the first accommodating cavity 410 and the second accommodating cavity 420 can be the same, wherein the first accommodating cavity 410 can be a plurality of continuously distributed, and the second accommodating cavity 420 can also be a plurality of continuously distributed, and the first accommodating cavity 410 and the second accommodating cavity 420 are arranged at intervals in the middle; optionally, the first accommodating cavity 410 and the second accommodating cavity 420 can also be arranged alternately at intervals; in other embodiments, the first accommodating cavity 410 and the second accommodating cavity 420 can also be arranged in other regular patterns, but at least a part of the first accommodating cavity 410 and the second accommodating cavity 420 are arranged at intervals. It can be understood that the transverse dimensions of the first accommodating cavity 410 and the second accommodating cavity 420 can be the same; in other embodiments, there is at least one group of the first accommodating cavity 410 and the second accommodating cavity 420 with the same transverse dimensions, while the transverse dimensions of other groups of the first accommodating cavity 410 and the second accommodating cavity 420 can be different. For example, taking the array arrangement as an example, the transverse dimensions of the first accommodating cavity 410 and the second accommodating cavity 420 arranged alternately in the first row can be the same, and can have a transverse dimension A, and the transverse dimensions of the first accommodating cavity 410 and the second accommodating cavity 420 arranged alternately in the second row can be the same, and have a transverse dimension B, and A and B are different, so that batch production of multiple same or different dimensions can be achieved. The transverse dimensions of the first accommodating cavity 410 and the second accommodating cavity 420 are the same, which can be understood that the transverse (for example, the maximum transverse) dimension of the annular surface 340 is equal to the transverse dimension of the first plane 310. Among them, the first accommodating cavity 410 and the second accommodating cavity 420 with the same transverse dimensions can be combined into a complete optical substrate 51 after subsequent injection molding. In some embodiments, the lateral dimension of the convex surface 320 is greater than or equal to the lateral dimension of the second plane 330. In other embodiments, the first plane 310 and the second plane 330 are parallel to each other, or the first plane 310 and the second plane 330 are collinearly disposed.
[0036] S12, providing a second mold 300, wherein the second mold 300 is located on a side of the first mold 200 facing the first accommodating cavity 410 and the second accommodating cavity 420;
[0037] The second mold 300 may be an integral flat plate, and of course, a corresponding accommodating cavity may also be provided, wherein the second mold 300 may be movable relative to the first mold 200 , for example, they may be pressed against each other.
[0038] S13, injecting molten light-transmitting material between the first mold 200 and the second mold 300 to fill the first accommodating cavity 410 and the second accommodating cavity 420;
[0039] In which, one or both of the first mold 200 and the second mold 300 may be provided with an injection hole, and the molten light-transmitting material may be injected through the injection hole. In other embodiments, there is a gap between the first mold 200 and the second mold 300, and the molten light-transmitting material may also be injected through the gap; wherein, the molten light-transmitting material may be a transparent molten material, for example, any one of polymethyl methacrylate, polycarbonate, plastic, resin or glass.
[0040] S14, pressing the first mold 200 and the second mold 300 together so that the molten light-transmitting material is fully attached to the first plane 310 and the convex surface 340, the second plane 330 and the annular surface 320;
[0041] The first mold 200 and the second mold 300 can be clamped by a fixture, one of which can be positioned and fixed, and then the other can be pressed in a fixed direction. For example, the first mold 200 having the first accommodating cavity 410 and the second accommodating cavity 420 can be fixed, and the second mold 300 can be pressed toward the first mold 200 by a pressure mechanism. In some embodiments, the two molds can also be controlled to move toward each other and pressed at the same time. Pressing can make the molten material fully fit with the first plane 22 and the convex surface 21, the second plane 31 and the annular surface 32, and this process can overflow the excess molten material.
[0042] It can be understood that the pressing process can make the molten material fully fit with the first plane 22 and the raised surface 21, the second plane 31 and the annular surface 32. In addition, it is also necessary to control the height of the corresponding optical substrate to be formed to meet the preset size. After pressing the first mold 200 and the second mold 300, the first accommodating cavity 410 and the second accommodating cavity 420 can be independent cavities, that is, the accommodating cavities are not connected to each other, and the subsequently formed optical substrates are independent of each other and not connected as a whole. Suction cups and other transfer processing can be used subsequently, which is conducive to flexible acquisition of the desired optical substrate; in other embodiments, the first accommodating cavity 410 and the second accommodating cavity 420 can be interconnected cavities, that is, the accommodating cavities can be connected to each other, and the subsequently formed optical substrates are connected to each other as a whole, so as to facilitate sorting and transfer processing, etc.
[0043] S15. After the molten light-transmitting material is cooled and solidified, the first mold 200 and the second mold 300 are demolded to obtain the first optical matrix 51 and the second optical matrix 52 formed after the molten light-transmitting material is solidified, wherein the structure of the first optical matrix 51 corresponds to the first plane 310 and the convex surface 320, and the structure of the second optical matrix 52 corresponds to the second plane 330 and the annular surface 320.
[0044] It can be understood that after the molten light-transmitting material is sufficiently cooled, it can be separated by a clamping mold such as a clamp, and the demolding can form an overall array of the first optical substrate 51 and the second optical substrate 52 connected together, or the first optical substrate 51 and the second optical substrate 52 are independent of each other; in other embodiments, the first optical substrate 51 and the second optical substrate 52 with the same lateral size can be a whole, and different lateral sizes constitute different arrays. The specific design can be based on actual conditions.
[0045] It can be understood that the above method of the present application does not need to cut the mirror material, which reduces the loss of raw materials and greatly reduces the production cost. By designing the first plane 310 and the convex surface 340, the second plane 330 and the annular surface 320 and multiple different design surfaces on one mold at the same time, and then injecting the molten material to fit the corresponding design surfaces, the number of molds developed is effectively reduced. Since the first plane 310 and the convex surface 340, the second plane 330 and the annular surface 320 are all on the same side, the molded first optical matrix 51 and the second optical matrix 52 can also be on the same side, so that in subsequent steps (such as coating), they can be processed at one time without having to process two separate surfaces separately, which effectively reduces the processing steps and greatly reduces the production cost.
[0046] In some embodiments, before demolding the first mold 200 and the second mold 300, it also includes determining whether the temperature of the injected molten light-transmitting material has dropped below the corresponding solidification point. If so, demolding can be performed. If not, cooling must be continued, for example, by using air cooling, water cooling, or natural heat dissipation.
[0047] In some embodiments, see Figure 2-5 , providing the first accommodating cavity 410 and the second accommodating cavity 420 of the first mold 200 with the same lateral dimensions; it can be understood that all the first accommodating cavities 410 and the second accommodating cavities 420 have the same lateral dimensions, that is, ensuring that all the first optical substrates 51 and the second optical substrates 52 can form a regular whole in subsequent processing without introducing other processing steps such as cutting and grinding, thereby reducing costs. In other embodiments, at least one group of first accommodating cavities 410 and second accommodating cavities 420 has the same lateral dimensions, and the lateral dimensions of the first accommodating cavities 410 and the second accommodating cavities 420 between multiple groups can be different, thereby batch-producing optical substrates of different sizes.
[0048] The first end of the first optical substrate 51 includes a first flat wall 512 and a recessed wall 511 lower than the first flat wall 512 , and the first flat wall 512 is arranged around the recessed wall 511 . The second end of the first optical substrate 51 opposite to the first end includes a first pressing wall 513 ; the first pressing wall 513 may be a wall pressed and formed by the second mold 300 .
[0049] The first end of the second optical base 52 includes a second flat wall 521 and an annular wall 522, and the second end of the second optical base 52 opposite to the first end includes a second pressing wall 523; the second pressing wall 523 can be a wall pressed into shape by the second mold 300, and the shapes of the second pressing wall 523 and the first pressing wall 513 can be the same or complementary, for example, the second pressing wall 523 and the first pressing wall 513 can both be flat walls.
[0050] The shape of the first plane 310 is the same as that of the first flat wall 512, the shape of the annular wall 522 is complementary to that of the annular surface 340, the shape of the second plane 330 is the same as that of the second flat wall 523, and the shape of the concave wall 511 is complementary to that of the convex surface 320. The complementarity here can be understood as the two still being a whole after being fitted together, without having an obvious gap, etc. For example, one of them is a concave surface and the other is a convex surface, and the two are still a whole after complementary matching. The first pressing wall 513 and the second pressing wall 523 can be the same or different in height, and their shapes can be complementary and adapted into a whole, for example, there is no gap, etc. In other embodiments, one of the second pressing wall 523 and the first pressing wall 513 has one or more protrusions, and the other has one or more corresponding grooves, and the two are still a whole after being mutually supplemented, without having an obvious gap, etc. Optionally, one of the second pressing wall 523 and the first pressing wall 513 is an upward inclined surface, and the other is a downward inclined surface, and the two are also formed into a whole after being mutually supplemented. After the above complementation, optical glue can be further added, or laser fusion and other technologies can be used.
[0051] In some embodiments, in conjunction with Figure 3 , a plurality of third accommodating cavities 430 are further provided on the second mold 300, and each third accommodating cavity 430 has the same transverse dimension and is coaxial with the first accommodating cavity 410 and the second accommodating cavity 420. It can be understood that by providing the third accommodating cavity 430 in the corresponding second mold 300, the depth of the first accommodating cavity 410 and the second accommodating cavity 420 in a single mold can be reduced, ensuring that the pressure when the molten material is injected is relatively small, which is conducive to the molten light-transmitting material fully fitting with the first plane 310 and the convex surface 340, the second plane 330 and the annular surface 320.
[0052] In some embodiments, see Figure 4-7, along the line direction from the first plane 310 to the second plane 330, there is a gap D1 between the first mold 200 and the second mold 300, and the molten light-transmitting material fills the gap to form a connecting layer 560. It can be understood that the gap D1 is conducive to the first optical substrate 51 and the second optical substrate 52 being connected as a whole through the connecting layer 560, which is conducive to batch transportation, clamping or processing, etc., wherein the gap (or connecting layer 560) is too thick, which is not conducive to subsequent cutting, and too thin, which is not conducive to the stability of the overall structure, wherein the gap or the connecting layer 560 thickness can be between 100-500 microns, for example, can be 100 microns, 300 microns, 400 microns or 500 microns, etc.
[0053] In some embodiments, see Figure 6-7 The connection layer 560 is disposed along the entire circumference of each optical substrate, thereby making the entire array more stable. In some embodiments, the connection layer 560 is disposed at intervals along the circumference of each optical substrate, thereby reducing the amount of light-transmitting material injected and reducing costs.
[0054] In some embodiments, see Figure 8 After obtaining the optical base 50 formed by curing the light-transmitting material, the method further includes coating the recessed wall 511 and the annular wall 522 with reflective layers 5111 and 5222 .
[0055] Among them, the reflective layer 5111 and the reflective layer 5222 can be metal or metal alloy, such as silver, aluminum, aluminum-magnesium alloy, etc., and can be coated by physical vapor deposition or chemical vapor deposition, such as mask coating, sputtering coating or ion plating. It can be understood that since the recessed wall 511 and the annular wall 522 are formed on the same side of the mold in the present application, the reflective layer can be plated on the recessed wall 511 and the annular wall 522 at one time, without coating one of them first and then inverting the optical substrate and coating the other wall, which reduces the processing steps of coating and effectively saves the production cost.
[0056] In some embodiments, see Fig.10 After the reflective layer is plated on the recessed wall 511 and the annular wall 522, the following steps are further included:
[0057] The microdisplay 700 is mounted on the second flat wall 521 of each second optical substrate 52 . The microdisplay 70 and the second flat wall 521 are closely attached to each other, and the lateral dimension of the microdisplay 70 is less than or equal to the lateral dimension of the second flat wall 521 .
[0058] In some other embodiments, the microdisplay 700 may also be installed before coating.
[0059] The micro display 700 may be Micro-LED (Micro Light-Emitting Diode), uLED (Micro Light Emitting Diode), Micro-oled (Micro Organic Light-Emitting Diode), LCoS (Liquid Crystal On Silicon), LCD (Liquid Crystal Display), DMD (Digital Micromirror Device) / DLP (Digital Light Processing) or LBS (Laser Beam Scanning), or any combination of these technologies. The micro display 700 may be bonded to the second flat wall 521 by optical glue or the like, and the thickness of the optical glue layer may be small enough not to affect the optical performance.
[0060] In some embodiments, see Fig.11 The manufacturing method further includes: cutting the connection structure between two adjacent substrates 51, 52 in a direction perpendicular to the first flat wall 512 to separate them into individual substrates. It is understandable that the cutting can be performed after demolding, after coating, or after the micro display 700 is installed. The cutting method can be mechanical or laser cutting, etc. The cutting can be along the gap 550 between the first optical substrate 51 and the second optical substrate 52. The gap can be formed by the first accommodating cavity 410 and the second accommodating cavity 420 that are spaced apart. During the injection molding process, no molten material will enter between the first accommodating cavity 410 and the second accommodating cavity 420 to maintain the gap 550, thereby ensuring that the side walls of the first optical substrate 51 and the second optical substrate 52 are not affected. In addition, this gap is also conducive to clamping or positioning by a clamp or the like.
[0061] In some embodiments, continue to refer to Figure 8 The method of the embodiment of the present application also includes: providing a baffle 600, the baffle 600 includes a blocking area 601, a first interval 602 and a second interval 603 arranged in a colinear manner, the blocking area 601 blocks the first flat wall 512 and the second flat wall 521, for example, metal particles and the like cannot pass through the blocking area 601; the opening of the first interval 602 corresponds to the width of the annular wall 522, and the opening of the second interval 603 corresponds to the width of the annular wall 522 and the width of the recessed wall 511; wherein the size of the second interval 603 can be larger than the first interval 602.
[0062] The metal or metal alloy reflective layer is plated on the annular wall 522 and the recessed wall 51 from the first spacer 602 and the second spacer 603. It can be understood that the above method does not need to make a baffle plate for the first flat wall 512 and the recessed wall (511) separately, and a baffle plate is made for the second flat wall (521) and the annular wall (522). It only needs to provide an integral baffle plate (such as a mask plate, etc.) to achieve the reflection layer plating of the first flat wall 512 and the second flat wall 521, which effectively reduces the cost of the baffle plate and the process of plating the reflection layer, and greatly reduces the cost.
[0063] In some embodiments, see Figure 11-13 The method of the embodiment of the present application also includes: providing a packaging sleeve 630, the sleeve 630 may be opaque; the sleeve 630 is provided with a first opening 632 and a second opening 634; the sleeve 630 may be made of black or other opaque materials, or the outer wall of the sleeve 630 may be coated with a black material, such as black epoxy resin, black silicone rubber, carbon black, nickel black, black chrome or Vanta black coatings or materials, etc. The sleeve 630 may be cylindrical, the first opening 632 is the end of the sleeve, and is configured to accommodate the first optical substrate 51 and the second optical substrate 52, and the size of the first opening 632 may be the same as the lateral size of the first optical substrate 51 and the second optical substrate 52. The size of the second opening 634 is smaller than the first opening 632. The second opening 634 can be in the middle of the sleeve 630. The second opening 634 can be one or multiple openings arranged at intervals. When there is one, the second opening 634 is designed not to occupy a whole circle of the circumference of the sleeve 630 as much as possible to ensure the mechanical support of the entire sleeve 630. Of course, in other embodiments, the sleeve 630 can be divided into a first sleeve and a second sleeve (not shown) arranged up and down, and a second opening 634 is formed between the first sleeve and the second sleeve. Optionally, the sleeve 630 can be cylindrical, and the sleeve 630 can also protect the first optical substrate 51 and the second optical substrate 52 inside.
[0064] Put one of the first optical substrate 51 and the second optical substrate 52 into the sleeve 630 along the first opening 632;
[0065] The placement of the first optical substrate 51 and the second optical substrate 52 may be related to the above-mentioned processes, such as the processes of coating the reflective layer and installing the microdisplay. If the coating of the reflective layer is completed first and the microdisplay 700 has not yet been installed, either the first optical substrate 51 or the second optical substrate 52 may be placed in the sleeve 630. If the process of installing the microdisplay has been completed, the second optical substrate 52 equipped with the microdisplay 700 may also be placed first, and then the first optical substrate 51 coated with the reflective layer may be placed.
[0066] An optical adhesive layer 710 is coated on the second pressing wall 523 or the first pressing wall 513 ; the optical adhesive layer 710 can be as thin as possible without affecting the light transmission efficiency after the lamination.
[0067] The other one of the first optical matrix 51 and the second optical matrix 52 is placed into the sleeve 630 along the first opening 632, and the optical adhesive layer 710 is adjacent to the second opening 634; the adjacent here can be understood as no matter which one of the first optical matrix 51 and the second optical matrix 52 is placed first, the entire side wall of the first optical matrix 51 and the second optical matrix 52 will not completely cover the second opening 634, and it can be understood that the end faces of the first optical matrix 51 and the second optical matrix 52 can be connected to the second opening 634 so that when the optical adhesive layer 710 is added later, the excess optical adhesive layer 710 overflows through the second opening 634.
[0068] The second pressing wall 523, the optical adhesive layer 710 and the first pressing wall 513 are attached, and the excess optical adhesive layer 710 overflows through the second opening 634. This step further presses the first optical substrate 51 and the second optical substrate 52 tightly, for example, reducing the presence of different transmission medium layers such as air.
[0069] It can be understood that the first optical substrate 51 coated with a reflective layer can be placed in the sleeve 630 first, and then the first optical substrate 51 and the second optical substrate 52 can be bonded together using the optical adhesive layer 710; in some embodiments, the second optical substrate 54 equipped with the micro display 700 can be placed in the sleeve 630 first, at which time the entire height of the second optical substrate 54 may not be completely higher than the second opening 634, and then the optical adhesive layer 710 is coated on the end face of the second optical substrate 54 facing away from the micro display 700, or the optical adhesive layer 710 is coated on the end face of the first optical substrate 51 facing away from the first flat wall 512. In other embodiments, glue can also be coated on both to form the optical adhesive layer 710.
[0070] In some embodiments, the sleeve 630 also includes a wiring hole, which can be located at a position of the sleeve 630 corresponding to the microdisplay 700, such as the bottom wall or side wall of the sleeve 630. The wiring hole can connect the electrical leads of the microdisplay 700 to other electrical components, such as a driving board or a battery.
[0071] In some embodiments, the manufacturing method of the present application further includes: placing the second optical substrate 52 equipped with the micro display 700 into the sleeve 630 along the first opening 632, and at least a portion of the micro display 700 is exposed relative to the wiring hole;
[0072] Coating the second pressing wall 523 or the first pressing wall 513 with an optical adhesive layer 710;
[0073] Put the first pressing wall 513 of the first optical substrate 51 into the sleeve 630 along the first opening 632;
[0074] The second pressing wall 523 , the optical adhesive layer 710 and the first pressing wall 513 are attached to each other, and the excess optical adhesive layer 710 overflows through the second opening 634 .
[0075] It can be understood that the sleeve 630 can be used to package the first optical matrix 51 and the second optical matrix 52, and the microdisplay 700 and the like can also be packaged together, so that the whole becomes a more complete module, which is conducive to subsequent applications, such as transportation, assembly with other equipment (such as glasses, head-mounted devices), etc.
[0076] In some embodiments, see Fig.13 , the method of the embodiment of the present application also includes:
[0077] Provide a light-transmitting protective layer 740; the light-transmitting protective layer 740 can be covered on the sleeve 630, and the light-transmitting protective layer 740 can be PMMA (polymethyl methacrylate), PC (polycarbonate) plastic, resin glass, etc. The light-transmitting protective layer 740 is covered on the first flat wall 512 and the recessed wall 511, and the size of the light-transmitting protective layer 740 is greater than or equal to the size of the first flat wall 52. The light-transmitting protective layer 740 can not change the propagation path of the original light, and can protect the first flat wall 512 and the recessed wall 511, reduce the wear and tear on them, and also reduce the entry of dust and other debris to affect their optical efficiency. In some embodiments, the size of the light-transmitting protective layer 740 can be the same as the size of the opaque packaging material 90, so that the overall structure is more regular, which is conducive to subsequent assembly.
[0078] In some embodiments, the micro display 700 may further include components such as a back panel, and the back panel may be connected to related electrical components by wires or flexible cables through the routing holes in the above embodiments.
[0079] The present application also provides an embodiment of a near-eye display device, which is manufactured by the above-mentioned manufacturing method. The near-eye display device as a whole can be cylindrical or prismatic. The entire size can be between 0.5 cubic millimeters and 5 cubic centimeters, such as 0.5 cubic millimeters, 1 cubic millimeter, 8 cubic millimeters, 1 cubic centimeter, 2 cubic centimeters, 5 cubic centimeters, etc. Its size is relatively small to the naked eye, and it is relatively easy to integrate into various other devices without affecting the appearance or large-area structure of the original device. For example, the augmented reality model display can be used in myopia glasses, hyperopia glasses, sunglasses, goggles, smart glasses or other head-mounted devices, etc., and has a good adaptation space.
[0080] The manufacturing method of the near-eye display device of the present application, that is, the near-eye display device, can adopt the method of setting different planes on the same side of the mold to form walls of different designs after injection molding, and can be plated with a reflective layer at one time, thereby reducing the number of molds and baffles for plating reflective layers, and further reducing the process of separately plating reflective layers on two different walls, thereby greatly reducing the production and preparation costs.
[0081] The above description is only a preferred embodiment of the present application and is not intended to limit the present application. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application.
Claims
1. A method for manufacturing a near-eye display device, characterized in that: include: A first mold (200) is provided, wherein the first mold (200) comprises a first accommodating cavity (410) and a second accommodating cavity (420) which are arranged at intervals, wherein the inner wall of the first accommodating cavity (410) is provided with a first plane (310) and a convex surface (320), wherein the first plane (310) is arranged around the convex surface (320), and the second accommodating cavity (420) is provided with a second plane (330) and an annular surface (340), wherein the annular surface (340) is arranged around the second plane (330); Providing a second mold (300), wherein the second mold (300) is located on a side of the first mold (200) facing the first accommodating cavity (410) and the second accommodating cavity (420); Injecting molten light-transmitting material between the first mold (200) and the second mold (300) to fill the first accommodating cavity (410) and the second accommodating cavity (420); Pressing the first mold (200) and the second mold (300) together so that the molten light-transmitting material is fully in contact with the first plane (310) and the convex surface (340), the second plane (330) and the annular surface (320); After the molten light-transmitting material is cooled and solidified, the first mold (200) and the second mold (300) are demolded to obtain a first optical matrix (51) and a second optical matrix (52) formed after the molten light-transmitting material is solidified, wherein the structure of the first optical matrix (51) corresponds to the first plane (310) and the convex surface (320), and the structure of the second optical matrix (52) corresponds to the second plane (330) and the annular surface (320).
2. The method for manufacturing a near-eye display device according to claim 1, wherein: The first accommodating cavity (410) and the second accommodating cavity (420) of the first mold (200) have the same lateral dimensions; The first end of the first optical substrate (51) comprises a first flat wall (512) and a recessed wall (511) lower than the first flat wall (512), the first flat wall (512) is arranged around the recessed wall (511), and the second end of the first optical substrate (51) opposite to the first end comprises a first pressing wall (513); The first end of the second optical substrate (52) comprises a second flat wall (521) and an annular wall (522), and the second end of the second optical substrate (52) opposite to the first end comprises a second pressing wall (523); The shape of the first plane (310) is the same as the shape of the first flat wall (512), the shape of the annular wall (522) is complementary to the shape of the annular surface (340), the shape of the second plane (330) is the same as the shape of the second flat wall (523), and the shape of the recessed wall (511) is complementary to the shape of the convex surface (320).
3. The method for manufacturing a near-eye display device according to claim 2, wherein: The second mold (300) is also provided with a plurality of third accommodating cavities (430), and each of the third accommodating cavities (430) has the same transverse dimensions and is coaxial with the first accommodating cavity (410) and the second accommodating cavity (420).
4. The method for manufacturing a near-eye display device according to claim 2, wherein: Along the line direction from the first plane (310) to the second plane (330), there is a gap (D1) between the first mold (200) and the second mold (300), and the molten light-transmitting material fills the gap to form a connecting layer (360).
5. The method for manufacturing a near-eye display device according to claim 2, wherein: After obtaining the optical matrix (50) formed by curing the light-transmitting material, the method further comprises coating the recessed wall (511) and the annular wall (522) with a reflective layer (5111, 5222).
6. The method for manufacturing a near-eye display device according to claim 5, characterized in that: After coating the recessed wall (511) and the annular wall (522) with a reflective layer, the method further comprises: The microdisplay (700) is mounted on the second flat wall (521) of each of the second optical substrates (52); the microdisplay (70) and the second flat wall (521) are tightly fitted, and the lateral dimension of the microdisplay (70) is less than or equal to the lateral dimension of the second flat wall (521).
7. The method for manufacturing a near-eye display device according to claim 2, wherein: The method further comprises: cutting the connection structure between two adjacent substrates (51, 52) in a direction perpendicular to the first flat wall (512) to separate the substrates into individual substrates.
8. The method for manufacturing a near-eye display device according to claim 2, wherein: The method further comprises: A packaging sleeve (630) is provided, wherein the sleeve (630) is opaque; the sleeve (630) is provided with a first opening (632) and a second opening (634); Putting one of the first optical substrate (51) and the second optical substrate (52) into a sleeve (630) along the first opening (632); Coating an optical adhesive layer (710) on the second pressing wall (523) or the first pressing wall (513); Putting the other of the first optical substrate (51) and the second optical substrate (52) into the sleeve (630) along the first opening (632), with the optical adhesive layer (710) adjacent to the second opening (634); The second pressing wall (523), the optical adhesive layer (710) and the first pressing wall (513) are attached together, and the excess optical adhesive layer (710) overflows through the second opening (634).
9. The method for manufacturing a near-eye display device according to claim 8, wherein: The sleeve (630) further comprises a wiring hole, and the method further comprises: The second optical substrate (52) equipped with a micro display (700) is placed into the sleeve (630) along the first opening (632), with the micro display (700) at least partially leaking out from the wiring hole; Coating the second pressing wall (523) or the first pressing wall (513) with an optical adhesive layer (710); Putting the first pressing wall (513) of the first optical substrate (51) into the sleeve (630) along the first opening (632); The second pressing wall (523), the optical adhesive layer (710) and the first pressing wall (513) are attached together, and the excess optical adhesive layer (710) overflows through the second opening (634).
10. The method for manufacturing a near-eye display device according to claim 1, wherein: Before demoulding the first mold (20) and the second mold (30), the method further includes determining whether the temperature of the light-transmitting material is below the solidification point, and if so, demoulding is performed; if not, the temperature of the light-transmitting material is controlled to be below the solidification point.
11. The method for manufacturing a near-eye display device according to claim 5, wherein: The coating of the reflective layer on the recessed wall (511) and the annular wall (522) comprises: A baffle (600) is provided, the baffle (600) comprising a shielding area (601), a first spacer (602) and a second spacer (603) arranged in a colinear manner, the shielding area (601) shields the first flat wall (512) and the second flat wall (521); an opening of the first spacer (602) corresponds to a width of the annular wall (522), and an opening of the second spacer (603) corresponds to a width of the annular wall (522) equal to a width of the recessed wall (511); The annular wall (522) and the recessed wall (51) are plated with a metal or metal alloy reflective layer from the first spacer (602) and the second spacer (603).
12. The method for manufacturing a near-eye display device according to claim 8, wherein: Also includes: Providing a light-transmitting protective layer (740); The light-transmitting protective layer (740) is covered on the first flat wall (512) and the recessed wall (511), and the size of the light-transmitting protective layer (90) is greater than or equal to the size of the first flat wall (52).
13. A near-eye display device, characterized in that: The near-eye display device is manufactured by the manufacturing method according to any one of claims 1-12.