Angled Lens Array Alignment for Stereoscopic Display Panels
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Solution Overview
Problem
Current stereoscopic display devices face challenges in precise alignment of lens arrays and display panels during manufacturing, leading to increased takt time and unfavorable mass production due to the elongated shapes of sub-pixels and alignment marks when viewed through the lens array, which complicates the alignment process and results in potential light leakage issues.
Innovation Solution
The display device incorporates a lens array with specific angled and curved surfaces, including a flat surface that connects inclined side surfaces of the lenses, allowing for precise alignment using sub-pixels in a non-emission state and the formation of light blockers with a length greater than 6 μm to reduce crosstalk and light leakage, enabling efficient manufacturing and improved image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lens arrays are used with traditional alignment methods, then alignment can be performed, but the alignment process becomes complex and time-consuming due to elongated shapes of sub-pixels and alignment marks when viewed through the lens array
Solution Approach 1:
The patent applies preliminary action by designing the lens array with pre-formed flat surfaces and inclined side surfaces that create distinct visual references. These features are prepared in advance during lens manufacturing, enabling simplified alignment operations later without requiring complex alignment procedures or additional processing steps.
Solution Approach 2:
The patent introduces flat surfaces as intermediary alignment references between the lens array and display panel. These flat surfaces act as mediators that provide clear visual markers for alignment, eliminating the need to directly align with elongated sub-pixel shapes or alignment marks that would otherwise be difficult to use for precise positioning.
2Reliability
If conventional lens arrays without light blockers are used, then manufacturing is simpler, but light leakage and crosstalk occur between adjacent sub-pixels
Solution Approach 1:
The patent applies local quality by adding light blockers only in specific locations where light leakage occurs between adjacent sub-pixels. The light blockers are positioned at the boundaries between lenses and have dimensions optimized for their specific function, rather than applying a uniform structure across the entire lens array. This localized approach maintains image quality while minimizing manufacturing complexity.
3Measurement precision
If the display panel is turned on during alignment, then alignment can be performed using emitted light, but production time increases due to the need to power on and off the display panel
Solution Approach 1:
The patent applies self-service by designing the lens array to provide its own alignment references through the flat surfaces and inclined side surfaces. These features create visible references that work with both emitted and ambient light, allowing alignment to be performed using existing light sources without requiring the display panel to be powered on or off for alignment purposes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for precise alignment of the lens array and display panel without turning on the display panel, reducing production time and preventing light leakage, thereby enhancing the manufacturing efficiency and image quality of stereoscopic displays.
Implementation Method 1
A first lens includes a first curved surface that is curved with respect to the third direction... A second lens includes a second curved surface that is curved in the third direction
Data Source
AI summary
A display device includes a display panel including sub-pixels arranged in a first direction and a second direction perpendicular to the first direction, and including light emitting surfaces in a third direction perpendicular to the first direction and the second direction, and lenses that overlap the sub-pixels in the third direction and to have a long side having an angle greater than 0 degree with respect to the second direction. A first lens includes a first curved surface and a first side surface connected to one edge of the first curved surface. A second lens includes a second curved surface and a second side surface connected to one edge of the second curved surface. The first lens and the second lens share a common lower surface. A flat surface connects the first side surface and the second side surface and extends parallel to the common lower surface.