Lens Array Layer Design for High-Resolution HMD Fabrication Yield
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Solution Overview
Problem
Current display devices for head-mounted display (HMD) devices face challenges in achieving high resolution and efficient fabrication, particularly in the design of the lens array layer and cover layer.
Innovation Solution
A display device is designed with a lens array layer that includes fine patterns and convex lenses, along with a cover layer that is formed without a structure that would prevent the overflow of a resin layer, allowing for a more efficient fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional lens array layer design is used, then the display device can be fabricated, but the fabrication yield is reduced due to resin layer overflow and unnecessary areas
Solution Approach 1:
The patent removes the unnecessary structure from the lens array layer that was preventing resin layer overflow. By extracting this redundant component, the design achieves both improved fabrication yield and reduced complexity, as the resin layer can now overflow naturally without causing defects
Solution Approach 2:
The patent allows the resin layer to overflow beyond the lens array layer boundaries, which was previously prevented by additional structures. This excessive action of allowing overflow simplifies the overall device structure while maintaining fabrication quality
2Area of stationary object
If the cover layer area is made larger to cover the lens array layer, then better coverage is achieved, but the fabrication efficiency decreases due to larger wafer substrate usage
Solution Approach 1:
The patent optimizes the area parameters of both the lens array layer and cover layer. By reducing the lens array layer area and adjusting the cover layer to match only the necessary display area, more devices can be fabricated per wafer substrate while maintaining adequate coverage
Data Source
AI summary
A display device, method of fabricating the same and head mounted display device comprising the same are provided. The display device includes a semiconductor substrate including a display area, a non-display area around the display area in plan view, and transistors, a light-emitting element layer above the semiconductor substrate, and including light-emitting elements in the display area, an encapsulation layer above the light-emitting element layer, a color filter layer above the encapsulation layer, and including color filters respectively overlapping the light-emitting elements, a lens array layer above the color filter layer, in the display area, in a portion of the non-display area, and including lenses respectively overlapping the light-emitting elements and having a convex cross-sectional shape, and pattern portions in the non-display area around the lenses, and a cover layer above the lens array layer.