Integrated support in switchable lenticular arrays

Abstract

A three-dimensional (3D) display, system, and method of fabrication and use thereof are described. The display includes a display panel having subpixels of different colors and a parallax-generating optic configured to direct light from the display panel to a viewer. The parallax-generating optic includes periodic optical elements extending in parallel. An integrated structural support extends from a base structure of at least some of the optical elements towards a cell wall to prevent or localize deformation. The structural supports have a density, positioning, orientation, and / or shape with a regular, random, or quasi-random arrangement.

Description

INTEGRATED SUPPORT IN SWITCHABLE LENTICULAR ARRAYSBACKGROUND

[0001] Multiview displays, such as three-dimensional (3D) displays and switchable privacy displays, face challenges in maintaining high visual quality while ensuring efficient fabrication processes. These challenges include issues related to optical element deformation, unwanted visual artifacts, and complex manufacturing requirements. Addressing these issues is desirable to advance display technology and improve user experience.BRIEF DESCRIPTION OF THE DRAWINGS

[0002] Various features of examples and embodiments in accordance with the principles described herein may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, where like reference numerals designate like structural elements, and in which:

[0003] Figure 1 shows a front-view schematic drawing of an example of a 3D display system that includes a 3D display.

[0004] Figure 2 shows a front-view drawing of an example of a display panel that includes an array of light-emitting diodes.

[0005] Figure 3 shows a front-view drawing of an example of a display panel that includes a multibeam backlight and a light valve array.

[0006] Figure 4 shows a front-view drawing of another example of a display panel.

[0007] Figure 5 shows a front-view drawing of an example of a parallaxgenerating optic that includes a lenticular lens array.

[0008] Figure 6 shows a cross-sectional view of the lenticular lens array of Figure 5.

[0009] Figure 7 shows a front-view drawing of an example of a parallaxgenerating optic that includes a parallax barrier having transmissive slits.

[0010] Figure 8 shows a cross-sectional view of the parallax barrier having transmissive slits of Figure 7.

[0011] Figure 9A shows a cross-sectional view of an example of a cell in a 3D display.

[0012] Figure 9B shows a cross-sectional view of an example of the cell in Figure 9A when pressure is applied.

[0013] Figure 10A shows a perspective view of an example of a lenticular array with integrated structural supports.

[0014] Figure 10B shows a cross-sectional view of the example of Figure 10A.

[0015] Figure 11 A shows a cross-sectional view of an example of a lenticular array with integrated structural supports.

[0016] Figure 1 IB shows a cross-sectional view of another example of a lenticular array with integrated structural supports.

[0017] Figure 12 shows a flowchart of an example of a method for creating a 2D or 3D display.

[0018] Certain examples and embodiments have other features that are one of in addition to and in lieu of the features illustrated in the above-referenced Figures. These and other features are detailed below with reference to the above-referenced Figures.DETAILED DESCRIPTION

[0019] In a 3D display, a display panel having an array of subpixels may display an image in a variety of orientations. Such an autostereoscopic 3D display may be used in both portrait and landscape orientation (dual orientation). The autostereoscopic display may include a parallax-generating optic configured to direct light from the display panel to the viewer. However, liquid crystal display (LCD) and organic light-emitting diode (OLED) display panels have pixel patterns that are not generally designed to operate using such an optical element; detrimental effects may result that include high crosstalk between views, reduced 3D resolution, as well as visual artifacts such as angular and spatial Moire patterns due to the periodicity and regularity of the patterns. Moreover, OLED panels may use different emission areas for different color subpixels which may lead to unequal 3D viewing performance between the different color channels.

[0020] In some embodiments of 3D displays, spacers that are integrated or deposited with an optical element may be used to alleviate some of the multitude ofresulting issues from the combination of elements above. For example, when lenticular arrays are used as optical elements, the lenticular array structures may be prone to deformation when coming into contact with an opposing cell wall. This deformation can lead to a loss of structural integrity and negatively impact the performance and visual output of the display. Preventing or localizing such deformation is thus desirable to maintain the functionality and longevity of the display.

[0021] In some further embodiments, spherical spacers, such as microspheres, may be used to provide separation between the lenticular array and the cell wall and prevent or localize deformation. Manufacturing of the structure, including the dispersion of microspheres, in this case may be ineffective and unreliable, and may further lead to aggregation of the spacers in the troughs between lenses if care is not taken during the manufacturing process. The aggregation may cause unwanted scattering and cross-talk, which can degrade the clarity and quality of the display, as well as introduce extra costs and processing complexities.

[0022] The preceding paragraphs are merely a summary of some technical details and challenges regarding autostereoscopic display systems. FIGS. 1-8 provide a more complete description of examples of the hardware of autostereoscopic displays. FIGS. 9- 12 provide a more complete description of optical elements with spacers and integration of such elements in a display.

[0023] As used herein, the article ‘a’ is intended to have its ordinary meaning in the patent arts, namely ‘one or more’. For example, ‘a subpixel’ means one or more subpixels and as such, ‘the subpixel’ means ‘the subpixel(s)’ herein. Also, any reference herein to ‘top’, ‘bottom’, ‘upper’, Tower’, ‘up’, ‘down’, ‘front’, back’, ‘first’, ‘second’, ‘left’ or ‘right’ is not intended to be a limitation herein. Herein, the term ‘about’ when applied to a value generally means within the tolerance range of the equipment used to produce the value, or may mean any value within 10% (e.g., 10%, 5%, 2%, 1%) of the value, or unless otherwise expressly specified. Further, the term ‘substantially’ as used herein means almost all or all of an amount within a numerical range of about 80% to about 100% of a value (or any value therebetween) or would otherwise be understood by one of skill in the art to encompass the term. For example, a substantially rectangular shape may deviate from a rectangular shape by being generally rectangular but havingnon-rectangular features, such as an inlet and / or projection. Moreover, examples herein are intended to be illustrative only and are presented for discussion purposes and not by way of limitation.

[0024] Figure 1 shows a schematic drawing of an example of a 3D display system 100 that includes an exploded view of a 3D display 102. The sign conventions shown in Figure 1 and used below assume that the 3D display 102 extends in an (x, y) plane, and that a z-axis extends away from the 3D display 102 and generally toward a viewer, along a direction that is orthogonal to a plane of the 3D display 102. Other sign conventions may also be used. The elements shown in Figure 1 may be contained within a single housing or some of the elements may be external to the housing.

[0025] As illustrated in Figure 1, the 3D display 102 may include a display panel 106 that may have an array of subpixels 108 configured to display an image according to stereo mapping coordinates associated with a viewer 104. The subpixels 108 may be located at subpixel locations in a grid having grid axes. Each subpixel 108 may generate light having a specified color. For example, the subpixels 108 may include red subpixels, green subpixels, and blue subpixels, which generate red light, green light, and blue light, respectively. Other color / wavelength schemes may also be used, such as the use of yellow subpixels. The subpixels 108 may be grouped into pixels, with each pixel including at least two subpixels 108 that produce light of different colors (e.g., 3 or 4 subpixels 108 of different colors may be used). Two possible configurations for the display panel 106 are described below and shown in Figures 2 and 3; other configurations may also be used.

[0026] Figure 2 shows a front-view drawing of an example of a display panel 106 A that includes an array 202 of light-emitting diodes 208, such as an array of organic light-emitting diodes. Each light-emitting diode 208 may correspond to a subpixel 108. The array 202 of light-emitting diodes 208 may include red light-emitting diodes 208R, green light-emitting diodes 208G, and blue light-emitting diodes 208B, which correspond to the red subpixels, green subpixels, and blue subpixels, respectively. A controller 118 (shown in Figure 1) may control the light-emitting diodes 208 individually or in one or more groups. Each light-emitting diode 208 may controllably generate light in response to an electrical signal provided by the controller 118 or by suitable light-emitting diodedriving circuitry in communication with the controller 118. The controller 118 may cause a specified light-emitting diode 208 to be directly powered with a power that varies as a function of an intensity in a corresponding location in the image. The power delivered to a light-emitting diode 208 may optionally be pulse-width modulated at a modulation frequency that is greater than may be perceived by a human eye. Using pulse-width modulation may simplify a design of a light-emitting diode array controller, because such modulation may generate an arbitrary average power level from a relatively small number of instantaneous power levels by varying a duty cycle of the power so supplied. In some examples, the array 202 of light-emitting diodes 208 may be arranged in a rectangular or square repeating pattern over a surface area 210 of the array 202. For example, the array 202 may have grid axes 204 that are orthogonal to each other. In some examples, the grid axes 204 may be parallel to edges 206 of the array 202 of light-emitting diodes 208.

[0027] Figure 3 shows a front-view drawing of an example of a display panel 106B that includes a backlight 302 and a light valve array 304. Although Figure 3 shows the backlight 302 and the light valve array 304 as being separated, in practice, the backlight 302 and the light valve array 304 may be in contact or may be located as close together as is practical. The backlight 302 may provide illumination having a uniform or substantially uniform intensity over a surface area of the backlight 302. The backlight 302 may provide illumination having a relatively broad spectrum, such as including most or all of the visible portion of the electromagnetic spectrum. The backlight 302 may provide the illumination into a continuum of propagation angles toward the light valve array 304. The backlight 302 may provide unmodulated illumination to the light valve array 304. The light valve array 304 may include light valves 308 that are individually controllable or controllable in one or more groups by the controller 118. Each light valve 308 may controllably attenuate the illumination from the backlight, such as in response to an electrical signal provided by the controller 118 or by suitable light valve driving circuitry in communication with the controller 118. The light valves 308 may have color filters that allow only a portion of the electromagnetic spectrum to pass through the light valve 308. For example, the light valves 308 may include red light valves 308R that have a red filter that allows only red light to pass through the red light valves 308R, green light valves 308G that have a green filter that allows only green light to pass through the greenlight valves 308G, and blue light valves 308B that have a blue filter that allows only blue light to pass through the blue light valves 308B. Other color schemes and numbers of colors may also be used as above. Suitable light valve arrays 304 may include liquid crystal light valves, electrophoretic light valves, and light valves based on electrowetting, and others. In some examples, the light valves 308 of the light valve array 304 may be arranged in a rectangular or square repeating pattern over a surface area 312 of the light valve array 304. For example, the light valve array 304 may have grid axes 204 that are orthogonal to each other. In some examples, the grid axes 204 may be parallel to edges 306 of the light valve array 304. The areas between the light valves 308, similar to the areas between the light-emitting diodes 208, may be designed to isolate light emission from the individual light valves 308. In some embodiments, optical elements such as reflective material may be used to guide light generated to and / or by the light valves 308, as well as the light-emitting diodes 208.

[0028] Figure 4 shows a front-view drawing of another example of a display panel. The subpixels 408 may include light-emitting diodes 208 of an array 202 of lightemitting diodes 208, as in Figure 2, or light valves 308 of a light valve array 304, as in Figure 3. Compared to a traditional red-green-blue subpixel arrangement, in which each pixel includes a red subpixel 408R (e.g., a light emitting diode that produces red light), a green subpixel 408G (e.g., a light emitting diode that produces green light), and a blue subpixel 408B (e.g., a light emitting diode that produces blue light), the pentile subpixel arrangement may include just two subpixels 408 (or light-emitting diodes) per pixel 402. The colors of the subpixels 408 in the display panel 106C may be arranged such that the missing color of a particular pixel 402 may be found in an adjacent pixel 404. Although some display panels may employ subpixel rendering in software, which may help smooth features in the image, the display panel 106C described herein may turn off subpixel rendering when the image is displayed. For a display panel 106C that turns off subpixel rendering when the image is displayed, a location of each subpixel 408 (e.g., each lightemitting diode) may be used for calculating the corresponding stereo mapping coordinate, rather than a center of a pixel 402 (e.g., the center of a specified group of subpixels 408 or a specified group of light-emitting diodes 208).

[0029] Referring again to Figure 1, the 3D display 102 may include a parallaxgenerating optic 110 that may direct light 112 corresponding to the image from the display panel 106 to the viewer 104. For example, the parallax-generating optic 110 may include a parallax optic or a parallax-generating optic. Two possible configurations for the parallax-generating optic 110 are described below and shown in Figures 5 and 6 and in Figures 7 and 8. Other configurations may also be used. Each of the configurations of Figures 5 and 6 and Figures 7 and 8 may be used in combination with any of the configurations of Figures 2 and 3.

[0030] Figure 5 shows a front-view drawing of an example of a parallaxgenerating optic 110A (e.g., the parallax optic or parallax-generating optic) that includes a lenticular lens array 502. Figure 6 shows a cross-sectional view of the lenticular lens array 502 of Figure 5. The lenticular lens array 502 may include an array of thin cylindrical lenslets 604 positioned to receive light from the display panel 106 and at least partially focus the received light to direct the light to specified regions proximate the viewer’s eyes.

[0031] Figure 7 shows a front-view drawing of an example of a parallaxgenerating optic HOB (e.g., the parallax optic or parallax-generating optic) that includes a parallax barrier 702 having transmissive slits 804. Figure 8 shows a cross-sectional view of the parallax barrier 702 having transmissive slits 804 of Figure 7. The parallax barrier 702 may include an array of opaque strips 806 and thin transmissive slits 804 arranged to occlude portions of a displayed image in left and right viewing regions. The transmissive slits 804 may be spatially arranged to ensure that the left / right image portions are only visible in the corresponding left / right viewing regions for which they are intended. The parallax barrier 702 may be provided by a static physical layer in which the slits are precisely positioned, or electronically generated on an adaptive intermediate liquid crystal display layer.

[0032] The parallax-generating optic 110, including one of the lenticular lens array 502 or the parallax barrier 702 having transmissive slits 804, may be operable with the display panel 106, including one of the array 202 of light-emitting diodes 208 or the backlight 302 and light valve array 304. Thus, the parallax-generating optic 110 may have periodic features having the same dimensions and functionality as described herein.

[0033] As illustrated in Figures 5 and 6, the parallax-generating optic 110 may be invariant along an optical axis (OA) having a slant angle, a, relative to the grid axes 204. For example, the parallax-generating optic 110 may have transmissive features, such as the lenslets or the transmissive slits, that are invariant along the optical axis and are periodic along an orthogonal axis that is orthogonal to the optical axis. As a specific example, the parallax-generating optic 110 may have transmissive slits that are parallel to the optical axis and are equally spaced along the orthogonal axis. As another specific example, the parallax-generating optic 110 may have cylindrical lenslets that are invariant in shape along the optical axis, have curvature along the orthogonal axis, and are equally spaced (e.g., with center-to-center spacing) along the orthogonal axis. The parallaxgenerating optic 110 may be angled by the slant angle, a, with respect to the grid axes 204, which may be parallel to edges 206 of the array 202 of light-emitting diodes 208 or edges 306 of the light valve array 304. For example, the slant angle may be within a specified angular tolerance of forty -five degrees, such as being between forty -four and forty-six degrees for a tolerance of + / - one degree, between forty-three and forty-seven degrees for a tolerance of + / - two degrees, between forty-two and forty-eight degrees for a tolerance of + / - three degrees, between forty-one and forty-nine degrees for a tolerance of + / - four degrees, between forty and fifty degrees for a tolerance of + / - five degrees, or another suitable angle or angular range. In some cases, the slant angle may be dependent on the type of display, which may include a liquid crystal light-emitting diode array or an organic light-emitting diode array with a pentile subpixel arrangement.

[0034] As illustrated in Figure 1, the 3D display 102 may include a material 114 disposed between the display panel 106 and the parallax-generating optic 110. In some examples, the material 114 may extend fully between the display panel 106 and the parallax-generating optic 110, such that a light ray originating at the display panel 106 passes only through the material 114 (and does not pass through any air or unfilled volume) before arriving at the parallax-generating optic 110. In other examples, the material 114 may occupy only a portion of the volume between the display panel 106 and the parallax-generating optic 110, such that a light ray originating at the display panel 106 passes through at least some of the material 114 and passes through a volume of air before arriving at the parallax-generating optic 110. The material 114 may have arefractive index denoted by n. The value of the refractive index n may be between about 1.3 and about 2, although other suitable values may also be used. Suitable materials may include glass, plastic, a transparent optical adhesive, and others. In some examples, the material 114 may be dispensed in a liquid form, then cured in place, such as by exposure to ultraviolet light or heat. In other examples, the material 114 may be manufactured as a solid unit and placed in its location in the 3D display 102. For example, the material 114 may function as a cover glass for the display panel 106. In some examples, the material 114 may function as a relatively precise spacing element. For example, the material 114 may be manufactured to have a specified thickness to within a specified thickness tolerance, and may set the spacing between the display panel 106 and parallax-generating optic 110 to have a value equal to the specified thickness when the 3D display 102 is assembled.

[0035] As illustrated in Figure 1, the 3D display 102 may include a viewer tracker 116 that may determine a location of the viewer 104. The viewer tracker 116 may provide a tracked position of the viewer 104 (e.g., of a head of the viewer 104, of one or both eyes of the viewer 104, or of another anatomical feature of the viewer 104). The viewer tracker 116 may be coupled to the controller 118, such as by providing viewer location data (shown in Figure 1 as coordinates xv, v, and zv) that represents a measured position or location of the viewer 104 (the position of the overall viewer is indicated by a particular value defined by the coordinates). The viewer tracker 116 may provide the viewer location data at regular or irregular intervals to the controller 118, depending on manual activation or stored in the memory 122. The viewer tracker 116 may include a camera configured to capture an image of the viewer 104. The viewer tracker 116 may further include an image processor (or general-purpose computer programmed as an image processor) configured to determine a position of the viewer 104 within the captured image to provide the tracked position. In some examples, the controller 118 may include the image processor of the viewer tracker 116, such as by performing operations with the same processing circuitry. In other examples, the controller 118 may be separate from the image processor of the viewer tracker 116. Other suitable viewer trackers may also be used, including viewer trackers based on lidar (e.g., using time-of- flight of reflected light over a scene to of view to determine distances to one or moreobjects in the scene, such as a viewer’s head or a viewer’s eyes) or other technologies. The controller 118 may use an output of the viewer tracker 116, among other data, to calculate the stereo mapping coordinates.

[0036] As illustrated in Figure 1, the 3D display system 100 may include a controller 118. The controller 118 may include a processor 120 and memory 122 storing instructions executable by the processor 120. The instructions may be executable by the processor 120 to perform data processing activities and / or track the position of the viewer to control the image display. The data processing activities may include, for subpixels 108 of the array of subpixels 108 of the display panel 106, determining the stereo mapping coordinates of the subpixels 108, and causing the display panel 106 to display the image according to the stereo mapping coordinates.

[0037] The controller 118 may be coupled to the 3D display 102 and / or the viewer tracker 116 wirelessly or through a wired connection. For example, the controller 118 may be mounted on a printed circuit board and coupled to the 3D display 102 through conductive traces on which the 3D display 102 is also mounted, while coupled to the viewer tracker 116 through WiFi (or another wireless protocol).

[0038] As above, the 3D display 102 may be used in dual orientation modes, which limits the slant angle to be relatively close to 45 degrees. However, in display panels that are substantially square, the use of pixels with equal aspect ratios prohibits the use of slants close to 45 degrees due to the resulting Moire patterns. To mitigate these issues, the pitch between the subpixels of a particular color in one of orthogonal directions is unequal. As used herein, the subpixel pitch is the pitch between subpixels of identical colors in different pixels. In some embodiments, the pitch may be between about 3 / 4 and about 4 / 3. The 3D display 102 may be an LCD panel or an OLED panel. Independent of the type of panel used, the 3D display 102 may use a variety of pixel layouts, such as a rectangular RGBG arrangement, pentile arrangement, or diamond pentile arrangement.

[0039] The light-emitting diodes 208, light valves 308, and / or subpixels 408 in the different examples may have different areas and / or shapes, although in display panels 106A, 106B, 106C, the light-emitting diodes 208, light valves 308, and / or subpixels 408may have substantially rectangular shapes. The controller 118 may control the light-emitting diodes 208, light valves 308, and / or subpixels 408 individually or in one or more groups. Each light-emitting diode 208, light valve 308, and / or subpixel 408 may controllably generate light in response to an electrical signal provided by the controller 118 or by suitable light-emitting diode driving circuitry in communication with the controller 118. The controller 118 may cause a specified light-emitting diode / light valve / subpixel 208, 308, 408 to be directly powered with a power that varies as a function of an intensity in a corresponding location in the image. The power delivered to a lightemitting diode 208, light valve 308, and / or subpixel 408 may be pulse-width modulated at a modulation frequency that is greater than may be perceived by a human eye.

[0040] Optical elements in a lenticular array can be provided in air or liquid-filled cells, and such elements may be susceptible to deformation. Figure 9A shows a cross- sectional view of an example of a cell in a 3D display. Figure 9B shows a cross-sectional view of an example of the cell in Figure 9A when pressure is applied, which may originate from the weight of the adjacent cell wall 902a (e.g., glass) or pressure on the wall 902a. The cell 900 contains an active region 904 surrounded by cell walls 902a, 902b. The cell walls 902a, 902b may be formed from a solid material that is transparent to light of the visible wavelengths, such as glass. The active region 904 may include optical elements 906a in a lenticular array. The active region 904 may be filled with air and / or a liquid transparent to light of the visible wavelengths, such as liquid crystal (LC). However, the optical element 906a shown in Figure 9A may be deformed to form a deformed optical element 906b as shown in Figure 9B when pressure is applied. This deformation occurs when the optical elements come into contact with the opposing cell wall (e.g., glass substrate), which can negatively impact the display's performance.

[0041] Microspheres may be deposited in the cell 900 after the optical elements 906a are provided on the cell wall 902b to prevent or localize this deformation; such microspheres, however, may have limited efficacy and reliability, as they may not provide consistent support across the entire lenticular array (discussed in further detail below). Additionally, the introduction of microspheres may add cost to the manufacturing process and increase manufacturing complexity. In addition to spacers potentially aggregating in undesired locations, introducing unwanted scattering of light and potentially leading to reduced image quality or increased crosstalk between differentviewing angles, inconsistent or unreliable spacing between the optical elements and the next layer of glass in the display stack can lead to variations in the LC layer thickness, potentially affecting the display's switching performance and overall 3D effect.

[0042] By integrating the structural supports directly into the lenticular array, these and other issues may be mitigated, leading to improved display performance and manufacturing efficiency. The integrated structural supports can be integral parts of the optical element structure, made from the same or similar material that matches or complements the optical elements at least in terms of index of refraction, and can be formed through processes like imprinting or injection molding. The integrated structural supports extend above an emission surface of the optical elements, providing a physical barrier that prevents direct contact between the surface of the optical elements and the cell wall. This design mitigates deformation of the optical elements, maintaining the optical performance and longevity of the display. The supports can be arranged in various configurations, including regular, periodic arrays or random and quasi-random patterns. The flexibility in arrangement helps minimize optical interference, such as Moire patterns, and allows for tailored solutions based on specific display requirements. The supports can take on different shapes, such as pillars, cones, or hemispheres, and can be distributed in low-density, sparse configurations to reduce their impact on optical performance. A low-density distribution is defined here to be an arrangement such that the total footprint area of the integrated support structures cover less than about 1% of the display surface area. The choice of shape and density (e.g., number of structural support members per unit area) is determined by the desired balance between structural support and visual clarity. By integrating the supports directly into the optical elements, the integrated structural supports provide consistent and reliable support, reducing manufacturing costs and complexity. This approach enhances the durability and performance in 3D displays.

[0043] Figure 10A shows a perspective view of an example of a lenticular array with integrated structural supports. Figure 10B shows a cross-sectional view of a portion of the example of Figure 10A with an integrated structural support 1006a. The example of Figure 10B includes a cell 1000 that contains an active region 1004 bounded in part by cell walls 1002a, 1002b. The cell walls 1002a, 1002b may be formed from a solidmaterial that is transparent to light of the visible wavelengths, such as glass, transmitted by a light emitter 1010. The light emitter 1010 may emit white light (and may have a reflector on a surface opposing the surface opposing the cell wall 1002b) or may be an array of that emits different colors, such as that shown above. The active region 1004 may include optical elements 1006 such as a lens in a lenticular array. The active region 1004 may be filled with air and / or a liquid transparent to light of the visible wavelengths, such as LC. Unlike the cell shown in Figure 9B, a structural support 1006a is integrated with at least a portion of the optical elements 1006. The integrated structural supports 1006a may be an integral part of the optical elements 1006 itself, made of the same or similar material. The lenticular array may thus include a base structure of optical elements 1006 and structural support of the integrated structural supports 1006a.

[0044] The integrated structural supports 1006a may be formed from glass or polymers such as polycarbonate or polymethyl methacrylate (PMMA), which offer transparency and durability. In some embodiments, composite materials such as a blend of polymers with reinforcing fibers may be used to increase the mechanical strength and durability of the integrated structural supports 1006a. The materials forming the integrated structural supports 1006a are chosen for optical clarity at the wavelengths of interest (here, wavelengths of visible light) and mechanical strength to ensure that the integrated structural supports 1006a do not interfere with the visual performance of the display. One or more anti -reflective coatings 1008 may be applied to a surface of the optical elements 1006 and / or the integrated structural supports 1006a to reduce reflections and improve optical clarity and reduce visual artifacts. Alternatively or additionally, introducing a textured surface to the optical elements 1006 and / or the integrated structural supports 1006a may enhance adhesion and stability of the structure.

[0045] The integrated structural supports 1006a extend above the surface of at least a portion of the lenticular array to support the opposing cell wall 1002 or layer, preventing direct contact between the lenticular surface and the cell wall 1002. As shown in Figure 10A, the integrated structural supports 1006a may be disposed in a low-density, sparse configuration across the display area to minimize impact on the optical performance of the display.

[0046] In particular, the integrated structural supports 1006a may be disposed in a number of arrangements, depending on the desired effect. In some embodiments, the integrated structural supports 1006a may be disposed in a uniform pattern across the optical elements 1006, such as in a regular, periodic array or grid. In some embodiments, the integrated structural supports 1006a may be disposed at random points on the optical elements 1006. In some embodiments, the integrated structural supports 1006a may be disposed at quasi -random positions on the optical elements 1006, such as a semi-random placement that may offer benefits of both regular and random arrangements. The integrated structural supports 1006a may be disposed in a gradient density across the display and / or to be minimally invasive to the display's visual output.

[0047] In any of these arrangements, the integrated structural supports 1006a may be disposed on each optical element 1006 or on only some of the optical elements 1006. For example, as shown in Figure 10A, the integrated structural supports 1006a may be disposed on alternating optical elements 1006 rather than every optical element 1006. In other embodiments, the integrated structural supports 1006a may be disposed in a random fashion (e.g., on adjacent optical elements 1006 in some portions of the lenticular array, while on other portions every other, third or other number of optical elements 1006). The integrated structural supports 1006a may also be formed at the same or different locations along each optical element 1006 on which the integrated structural supports 1006a is present. As shown in Figure 10A, the integrated structural supports 1006a can be disposed along different (lateral) positions along the optical elements 1006.

[0048] In some cases, positioning the integrated structural supports 1006a in random or quasi-random positions may help to reduce unwanted Moire patterns in the display. Accordingly, placement of the integrated structural supports 1006a may be tailored to address specific optical challenges or requirements of the display. Varying the density of the integrated structural supports 1006a across the display may provide targeted reinforcement where desired, optimizing material usage and performance. In addition, implementing clusters of the integrated structural supports 1006a in high-stress areas may prevent or localize deformation and enhance overall structural integrity.

[0049] In addition to adjusting the position and / or the density of the integrated structural supports 1006a, the orientation of the integrated structural supports 1006a maybe the same or at least some of the integrated structural supports 1006a may be different. Thus, in some cases, the apexes of some of the integrated structural supports 1006a may directly oppose the opposing cell wall 1002a, while the apexes of some of the integrated structural supports 1006a may be offset up to about 45° from normal to the opposing cell wall 1002a (clockwise or anti -clockwise). As with the density and positioning, the orientation may have a regular, random, or quasi-random arrangement on the optical elements 1006.

[0050] In an example, the integrated structural supports 1006a may provide improved reliability by providing more consistent and reliable support compared to dispersed spacers. The integrated structural supports 1006a may lower manufacturing costs and simplify the production process by eliminating the integration of separate, discrete spacer elements in or with the structure. Moreover, the ability to design and manufacture the integrated structural supports 1006a as part of the lenticular array allows for more precise control over placement and dimensions and permits a sparse arrangement to be used, thereby minimizing the impact of the integrated structural supports 1006a on the display's optical characteristics while still providing the support to prevent or localize deformation.

[0051] The integrated structural supports 1006a may be formed through the same process as the optical element 1006, such as imprinting or injection molding. For example, to form the overall structure using imprinting, a mold is pressed with the desired pattern of optical elements and supports into a substrate material. The mold is designed to create both the lenticular lenses and the integrated structural supports in a single step, ensuring precise alignment and integration. Alternatively, for injection molding, the substrate material may be injected into a mold that contains the negative pattern of the optical elements and supports. The material fills the mold, forming the integrated structure as the material in the mold cools and solidifies.

[0052] The integrated structural supports 1006a shown in Figures 10A and 10B are substantially semi-cylindrical. However, other shapes may be used as the integrated structural supports 1006a such as square or rectangular pillars, hemispheres or other arcuate shapes, cones, hexagonal or honeycomb structures (which may provide support while minimizing material usage, offering a balance between strength and optical clarity),and wave or ripple structures (which may enhance flexibility and adaptability, allowing the supports to conform to varying pressures and reduce stress on the optical elements). Figure 11 A shows a cross-sectional view of an example of a lenticular array with integrated structural supports. In particular, the cross-sectional view in Figure 11 A shows that the structure 1100a includes an optical element 1106 with an integrated structural support 1106a having a pillar shape disposed on the cell wall 1102. Figure 1 IB shows a cross-sectional view of another example of a lenticular array with integrated structural supports. The cross-sectional view in Figure 1 IB shows that the structure 1100b includes an optical element 1106 with an integrated structural support 1106a having a conical shape disposed on the cell wall 1102. Like the density, positioning, and orientation, the type and distribution of shapes may have a regular, random, or quasi-random arrangement on the optical elements 1106.

[0053] In some embodiments, conductive pathways may be integrated within the integrated structural support. This may involve embedding conductive materials into the structural supports during the fabrication process. This integration allows the integrated structural support to serve dual functions: providing structural support and facilitating electrical connections within the display. Conductive materials, such as metal traces or conductive polymers, may be incorporated into the integrated structural support. These conductive materials may be selected for electrical conductivity and compatibility with the integrated structural support material. This may allow the conductive pathways to be strategically placed to connect various electronic components without interfering with the optical performance. During the imprinting or injection molding process, the conductive materials may be embedded into the integrated structural support by layering the conductive material within the mold or by using a co-molding technique that integrates the conductive pathways as the integrated structural support are formed. The conductive pathways enable electrical connections between different parts of the display, such as connecting the display panel to control circuits or sensors. This integration reduces additional wiring, simplifying the design and potentially enhancing the display's reliability and performance.

[0054] Figure 12 shows a flowchart of an example of a method for creating a 2D or 3D display. Only some of the steps used to create the display are shown forconvenience in the method 1200; other steps, such as cleaning of the various elements may be present. The method 1200 is but one method for creating the display; other suitable methods may also be used.

[0055] At operation 1202, a material is selected for the optical elements and integrated structural supports that offer transparency and durability, such as polycarbonate or PMMA.

[0056] At operation 1204, the arrangement of the integrated structural supports (ISS) may be determined. The arrangement may be, for example, in a regular, periodic array or a random pattern. The shape and density of the integrated structural supports may be adjusted based on the specific display.

[0057] At operation 1206, the selected material may be used to create the combined structure that includes the optical elements and the integrated structural supports. This may include creating a mold that includes the negative pattern of the combined structure and using imprinting or injection molding to form the combined structure. For imprinting, the mold is pressed into the substrate material to create the desired pattern. For injection molding, the substrate material is injected into the mold, allowing the material to fill the pattern and solidify (e.g., using temperature and / or UV curing). Other techniques can similarly be used in operation 1204, including but not limited to material deposition or etching. In some embodiments, conductive materials may be formed in the combined structure during formation.

[0058] In some embodiments, sensors may be embedded in the integrated structural supports during formation of the combined structure. The embedded sensors may provide real-time feedback on various display conditions, such as temperature, pressure, or mechanical stress. The sensors may enable dynamic adjustments to optimize display performance and ensure the longevity of the optical elements. The types of sensors may include temperature sensors, which monitor the thermal conditions within the display, allowing for adjustments to prevent overheating and maintain optimal operating temperatures; pressure sensors, which may detect changes in pressure that may affect the structural integrity of the display, enabling proactive measures to prevent or localize deformation; and strain gauges, which may measure mechanical stress on the optical elements, providing data to adjust support configurations and reduce stressconcentrations. Different types of sensors may be disposed in different locations in the display, or the sensors may be uniformly distributed throughout the display. The embedded sensors may continuously collect data, which may be transmitted to a processor within the display system. The data may be analyzed to make real-time adjustments, such as modifying display settings or activating cooling mechanisms.

[0059] At operation 1208, surface treatments, such as anti -reflective coatings or micro-textures, may be applied to the optical elements and / or the integrated structural supports to enhance optical clarity and adhesion. These treatments can be applied to both.

[0060] At operation 1210, the display may be assembled by aligning and securing the optical elements with the integrated structural supports in place. The integrated structural supports are disposed to extend above the optical elements. The alignment, placement, and integrity of the integrated structural supports and optical elements may be verified and any defects or misalignments addressed to ensure optimal performance.

[0061] At operation 1212, the assembled optical elements and integrated structural supports may be integrated into the overall display. For example, LC material may be added between the optical elements and the cells formed by the sealed structure. In other embodiments, LC material may not be added - instead, a gas (e.g., air) or other material may be used.

[0062] Other operations may be implemented to form the display, including coupling the lenticular array and LC material to a transparent substates such as glass. Electrodes to control the individual cells may be provided across the structure, and other operations may be used to create the display.

[0063] To further illustrate the systems and related methods disclosed herein, a non-limiting list of examples is provided below. Each of the following non-limiting examples may stand on its own or may be combined in any permutation or combination with any one or more of the other examples.

[0064] Example l is a three-dimensional (3D) display comprising: a display panel configured to provide light of different colors, the display panel configured to display an image to a viewer; and a parallax-generating optic configured to direct light from the display panel to the viewer, the parallax-generating optic comprising periodic optical elements extending in parallel and having substantially identical base structures, whereinone or more of the periodic optical elements includes an integrated structural support that is integrated with and extends from a respective base structure toward a cell wall.

[0065] In Example 2, the subject matter of Example 1 includes, wherein the integrated structural support is formed from an identical material as the respective base structure.

[0066] In Example 3, the subject matter of Examples 1-2 includes, wherein fewer than all of the periodic optical elements include a corresponding integrated structural support.

[0067] In Example 4, the subject matter of Examples 1-3 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the multiple integrated structural supports are randomly or quasi -randomly disposed along the respective base structures to minimize Moire patterns.

[0068] In Example 5, the subject matter of Examples 1-4 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are randomly or quasi -randomly oriented on the base structures with regard to the cell wall.

[0069] In Example 6, the subject matter of Examples 1-5 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are arranged in a regular periodic array.

[0070] In Example 7, the subject matter of Examples 1-6 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports have shapes selected from a group of shapes that include pillar, hemisphere, cylinder, semi-cylinder, rectangle, sphere, and cone.

[0071] In Example 8, the subject matter of Examples 1-7 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are disposed in a low-density sparse arrangement.

[0072] In Example 9, the subject matter of Examples 1-8 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are identical in shape.

[0073] In Example 10, the subject matter of Examples 1-9 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports include an anti -reflective coating to enhance optical clarity.

[0074] In Example 11, the subject matter of Examples 1-10 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are composed of composite materials for enhanced strength.

[0075] In Example 12, the subject matter of Examples 1-11 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are integrated with conductive pathways for electrical connections.

[0076] In Example 13, the subject matter of Examples 1-12 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports include embedded sensors for real-time feedback.

[0077] In Example 14, the subject matter of Examples 1-13 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are designed with micro-textures to enhance adhesion.

[0078] In Example 15, the subject matter of Examples 1-14 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are positioned to provide targeted reinforcement in high-stress areas.

[0079] In Example 16, the subject matter of Examples 1-15 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are formed with a gradient density across the display.

[0080] In Example 17, the subject matter of Examples 1-16 includes, wherein the one or more of the periodic optical elements include multiple integrated structuralsupports, and the integrated structural supports are designed to be minimally invasive to a visual output of the 3D display.

[0081] In Example 18, the subject matter of Examples 1-17 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are formed with wave or ripple designs.

[0082] In Example 19, the subject matter of Examples 1-18 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are formed using imprinting techniques.

[0083] In Example 20, the subject matter of Examples 1-19 includes, wherein the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are formed using injection molding techniques.

[0084] Example 21 is a three-dimensional (3D) display system comprising: a display panel configured to provide light of different colors, the display panel configured to display an image to a viewer; a parallax-generating optic configured to direct light from the display panel to the viewer, the parallax-generating optic comprising periodic optical elements extending in parallel and having identical base structures, each of at least some of the periodic optical elements having an integrated structural support that extends from the base structure towards a cell wall and is integrated with a corresponding base structure; and a processor configured to control the display panel.

[0085] In Example 22, the subject matter of Example 21 includes, wherein the integrated structural support is formed from an identical material as the corresponding base structure.

[0086] In Example 23, the subject matter of Examples 21-22 includes, wherein the integrated structural supports extend from fewer than all of the base structures.

[0087] In Example 24, the subject matter of Examples 21-23 includes, wherein the integrated structural supports are randomly or quasi -randomly disposed along the base structures to minimize Moire patterns.

[0088] In Example 25, the subject matter of Examples 21-24 includes, wherein the integrated structural supports are randomly disposed along the base structures or oriented on the base structures with regard to the cell wall, or the integrated structuralsupports are quasi -randomly disposed along the base structures or oriented on the base structures with regard to the cell wall.

[0089] In Example 26, the subject matter of Examples 21-25 includes, wherein the integrated structural supports are arranged in a regular periodic array.

[0090] In Example 27, the subject matter of Examples 21-26 includes, wherein the integrated structural supports have shapes selected from a group of shapes that include pillar, hemisphere, cylinder, rectangle, sphere, and cone.

[0091] In Example 28, the subject matter of Examples 21-27 includes, wherein the integrated structural supports are disposed in a low-density sparse arrangement.

[0092] In Example 29, the subject matter of Examples 21-28 includes, wherein the integrated structural supports are identical in shape.

[0093] In Example 30, the subject matter of Examples 21-29 includes, wherein the integrated structural supports include an anti -reflective coating to enhance optical clarity.

[0094] In Example 31, the subject matter of Examples 21-30 includes, wherein the integrated structural supports are composed of composite materials for enhanced strength.

[0095] In Example 32, the subject matter of Examples 21-31 includes, wherein the integrated structural supports are integrated with conductive pathways for electrical connections.

[0096] In Example 33, the subject matter of Examples 21-32 includes, wherein the integrated structural supports include embedded sensors for real-time feedback to the processor.

[0097] In Example 34, the subject matter of Examples 21-33 includes, wherein the integrated structural supports are designed with micro-textures to enhance adhesion.

[0098] In Example 35, the subject matter of Examples 21-34 includes, wherein the integrated structural supports are positioned to provide targeted reinforcement in high- stress areas.

[0099] In Example 36, the subject matter of Examples 21-35 includes, wherein the integrated structural supports are formed with a gradient density across the display.

[0100] In Example 37, the subject matter of Examples 21-36 includes, wherein the integrated structural supports are designed to be minimally invasive to a visual output of the 3D display.

[0101] In Example 38, the subject matter of Examples 21-37 includes, wherein the integrated structural supports are formed with wave or ripple designs for enhanced flexibility.

[0102] Example 39 is a method for manufacturing a three-dimensional (3D) display, the method comprising integrating a display panel configured to provide light of different colors with a parallax-generating optic configured to direct light from the display panel to a viewer, the parallax-generating optic comprising periodic optical elements, each of at least some of the periodic optical elements having an integrated structural support (ISS) that extends from a base structure towards a cell wall and is integrated with the base structure.

[0103] In Example 40, the subject matter of Example 39 includes, forming the ISS using imprinting.

[0104] In Example 41, the subject matter of Examples 39-40 includes, forming the ISS using injection molding.

[0105] In Example 42, the subject matter of Examples 39-41 includes, embedding conductive pathways within the ISS for electrical connections.

[0106] In Example 43, the subject matter of Examples 39-42 includes, embedding sensors within the ISS for real-time feedback to a processor that controls the display panel.

[0107] In Example 44, the subject matter of Examples 39-43 includes, applying micro-textures to the ISS to enhance adhesion.

[0108] In Example 45, the subject matter of Examples 39-44 includes, forming the ISS with a gradient density across the 3D display.

[0109] In Example 46, the subject matter of Examples 39-45 includes, applying a protective coating over the ISS after formation.

[0110] In Example 47, the subject matter of Examples 39-46 includes, aligning the ISS to provide targeted reinforcement in high-stress areas.

[0111] In Example 48, the subject matter of Examples 39-47 includes, wherein the ISS are designed to be minimally invasive to a visual output of the 3D display.

[0112] In Example 49, the subject matter of Examples 39-48 includes, forming the ISS with wave or ripple designs.

[0113] In Example 50, the subject matter of Examples 39-49 includes, curing the optical elements after forming the optical elements.

[0114] In Example 51, the subject matter of Examples 39-50 includes, wherein the ISS are designed to minimize Moire patterns.

[0115] Example 52 is at least one machine-readable medium including instructions that, when executed by processing circuitry, cause the processing circuitry to perform operations to implement of any of Examples 1-51.

[0116] Example 53 is an apparatus comprising means to implement of any of Examples 1-51.

[0117] Example 54 is a system to implement of any of Examples 1-51.

[0118] Example 55 is a method to implement of any of Examples 1-51.

[0119] Thus, there have been described examples and embodiments of a 3D display system and method that may display an image according to stereo mapping coordinates associated with a viewer. The above-described examples are merely illustrative of some of the many specific examples that represent the principles described herein. Clearly, those skilled in the art may readily devise numerous other arrangements without departing from the scope as defined by the following claims.

Claims

CLAIMSWhat is claimed is:

1. A three-dimensional (3D) display comprising: a display panel configured to provide light of different colors, the display panel configured to display an image to a viewer; and a parallax-generating optic configured to direct light from the display panel to the viewer, the parallax-generating optic comprising periodic optical elements extending in parallel and having substantially identical base structures, wherein one or more of the periodic optical elements includes an integrated structural support that is integrated with and extends from a respective base structure toward a cell wall.

2. The 3D display of claim 1, wherein the integrated structural support is formed from an identical material as the respective base structure.

3. The 3D display of claim 1, wherein fewer than all of the periodic optical elements include a corresponding integrated structural support.

4. The 3D display of claim 1, wherein: the one or more of the periodic optical elements include multiple integrated structural supports, and the multiple integrated structural supports are randomly or quasi -randomly disposed along the respective base structures to minimize Moire patterns.

5. The 3D display of claim 1, wherein: the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are randomly or quasi -randomly oriented on the base structures with regard to the cell wall.

6. The 3D display of claim 1, wherein:the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are arranged in a regular periodic array.

7. The 3D display of claim 1, wherein: the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports have shapes selected from a group of shapes that include pillar, hemisphere, cylinder, semi-cylinder, rectangle, sphere, and cone.

8. The 3D display of claim 1, wherein: the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are disposed in a low-density sparse arrangement.

9. The 3D display of claim 1, wherein: the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports are identical in shape.

10. The 3D display of claim 1, wherein: the one or more of the periodic optical elements include multiple integrated structural supports, and the integrated structural supports include an anti -reflective coating to enhance optical clarity.

11. A three-dimensional (3D) display system comprising: a display panel configured to provide light of different colors, the display panel configured to display an image to a viewer;a parallax-generating optic configured to direct light from the display panel to the viewer, the parallax-generating optic comprising periodic optical elements extending in parallel and having identical base structures, each of at least some of the periodic optical elements having an integrated structural support that extends from the base structure towards a cell wall and is integrated with, and is formed from an identical material as, a corresponding base structure; and a processor configured to control the display panel.

12. The 3D display system of claim 11, wherein the integrated structural supports are identical in shape.

13. The 3D display system of claim 11, wherein the integrated structural supports extend from fewer than all of the base structures.

14. The 3D display system of claim 11, wherein the integrated structural supports are randomly disposed along the base structures or oriented on the base structures with regard to the cell wall, or the integrated structural supports are quasi -randomly disposed along the base structures or oriented on the base structures with regard to the cell wall.

15. The 3D display system of claim 11, wherein the integrated structural supports are arranged in a regular periodic array.

16. The 3D display system of claim 11, wherein the integrated structural supports have shapes selected from a group of shapes that include pillar, hemisphere, cylinder, rectangle, sphere, and cone.

17. The 3D display system of claim 11, wherein the integrated structural supports are disposed in a low-density sparse arrangement.

18. A method for manufacturing a three-dimensional (3D) display, the method comprising:integrating a display panel configured to provide light of different colors with a parallax-generating optic configured to direct light from the display panel to a viewer, the parallax-generating optic comprising periodic optical elements, each of at least some of the periodic optical elements having an integrated structural support (ISS) that extends from a base structure towards a cell wall and is integrated with the base structure.

19. The method of claim 18, comprising forming the ISS using imprinting.

20. The method of claim 18, comprising forming the ISS using injection molding.

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