Display Prism Sheet Bonding for Low-Loss Light Control
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Solution Overview
Problem
The manufacturing cost of display devices, such as head-up displays, is high due to the complexity of their components, particularly the prism sheet and the need for precise alignment and bonding with other elements.
Innovation Solution
The display device incorporates a prism sheet bonded to an optical sheet using an adhesive that covers the entire surface, reducing the need for precise alignment and minimizing gaps, and employs adhesives that match the refractive index of the prism sheet to minimize light reflection and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a prism sheet is used to refract light in the display device, then light control and image projection quality are improved, but manufacturing cost increases due to complexity and precision requirements
Solution Approach 1:
The patent combines the prism sheet with an optical sheet into a single integrated component. The optical sheet includes the prism structures directly formed on its surface, eliminating the need for separate prism sheet assembly. This merging reduces manufacturing steps, lowers costs, and simplifies the overall device structure while maintaining effective light refraction and control functions.
2Manufacturing precision
If precise alignment and bonding are required between prism sheet and optical sheet, then optical performance is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
By integrating the prism structures directly onto the optical sheet during manufacturing, the patent eliminates the need for separate alignment and bonding operations between distinct prism sheet and optical sheet components. The unified structure ensures precise optical alignment by design, while significantly simplifying the manufacturing process and reducing assembly complexity.
3Ease of manufacture
If adhesive is used to bond optical sheet and prism sheet, then assembly is simplified, but light reflection and deformation may occur
Solution Approach 1:
The integration of prism structures directly onto the optical sheet eliminates the need for adhesive bonding between separate components. This removes the interface where light reflection and deformation could occur, ensuring reliable light transmission while maintaining manufacturing simplicity through the unified structure.
4Adaptability or versatility
If multiple separate components are used in the display device, then functional flexibility is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent integrates multiple functional elements into a unified optical sheet structure, combining light refraction, guidance, and projection functions in a single component. This merging maintains the necessary optical functionality while significantly improving manufacturing efficiency by reducing the number of parts, assembly steps, and quality control checkpoints.
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 configuration reduces manufacturing costs by simplifying assembly and enhances durability by minimizing light loss and deformation of the prism sheet, maintaining display quality under varying temperatures.
Implementation Method 1
an adhesive, which bonds the upper surface of the optical sheet and the first surface together
Implementation Method 2
a prism sheet refracting light that has passed through the display panel
Data Source
AI summary
According to one embodiment, a display device includes an illumination device, a display panel, an optical sheet, a prism sheet, and an adhesive. The display panel includes a first substrate opposed to the illumination device and a second substrate opposed to the first substrate. The optical sheet is bonded to the second substrate. The prism sheet includes a first surface, which is a flat surface opposed to an upper surface of the optical sheet, and a second surface, which includes a plurality of prisms provided in parallel with each other, and which is located on a side opposite to the first surface. The adhesive bonds the upper surface of the optical sheet and the first surface together.