Display Lens Array Integration for 3D Viewing Control

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Solution Overview

Problem

Existing display devices struggle to effectively provide three-dimensional (3D) effects and viewing angle control through lens arrays without the need for separate alignment and attachment, which can complicate manufacturing processes.

Innovation Solution

A display device design that integrates a lens array directly onto a substrate, using a laser to modify the lens array substrate's properties and then etching it to form lenses, allowing for direct contact and eliminating the need for separate adhesives or alignment during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a lens array is attached to the display panel separately, then the display device can provide 3D effects and viewing angle control, but the manufacturing process becomes complicated requiring separate alignment and attachment steps

Engineering Contradiction:

Improve3D effect and viewing angle control capabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the lens array and display panel into a single integrated structure. The lens array is formed directly on the substrate using laser irradiation to create recesses, eliminating the need for separate attachment. This integration resolves the contradiction by combining two previously separate components into one, maintaining 3D functionality while simplifying manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies preliminary action by using laser irradiation to pre-form the lens structures directly on the substrate before the display panel is completed. The laser creates recesses that are then filled with molding compound to form the lenses, preparing the optical structures in advance and eliminating subsequent alignment and attachment steps.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a lens array is attached separately to the display panel, then optical functionality is achieved, but additional adhesives and support structures are required

Engineering Contradiction:

Improveoptical functionalityVSAvoidadditional materials such as adhesives

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent combines the lens array formation process with the substrate manufacturing process. The lenses are formed directly on the substrate using laser irradiation and molding compound, eliminating the need for separate adhesives and support structures. This integration reduces material quantity while maintaining optical reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The substrate itself serves dual purposes: as the structural base and as the mounting surface for the lens array. The laser-created recesses in the substrate directly hold the lenses without requiring additional adhesives or support structures, allowing the substrate to serve multiple functions and reduce material requirements.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If laser irradiation is applied to the lens array substrate, then the physical properties are modified to enable lens formation, but energy consumption increases

Engineering Contradiction:

Improvelens formation precisionVSAvoidlaser energy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies local quality by using laser irradiation only at specific predetermined positions on the substrate where lenses are needed. The laser modifies the physical properties of the substrate locally at these positions, creating recesses for lens formation. This localized approach achieves precise lens formation while minimizing overall energy consumption compared to treating the entire substrate.

Inventive Principle:

Principle #3Local quality

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 method enables efficient manufacturing of display devices with 3D and viewing angle control capabilities by simplifying the integration of lens arrays, reducing manufacturing complexity and eliminating the need for additional support structures.

Implementation Method 1

irradiating a laser to a predetermined position of a lens array substrate

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

physical properties of the lens array substrate at the predetermined position are different from physical properties of the lens array substrate in an area of the lens array substrate other than the predetermined position

Methodology Applied

Scientific EffectThermal modification of material bonds: Heat Treatment

Implementation Method 3

forming a lens array by etching a second surface opposite to the first surface of the lens array substrate

Methodology Applied

Scientific EffectEtching:

Data Source

PatentUS12352984B2Display device including a lens array and method of manufacturing the same

Publication Date: 2025.07.08 SAMSUNG DISPLAY CO LTD

AI summary

A display device includes: a first substrate; thin-film transistors disposed on a first surface of the first substrate; light emitting elements connected to corresponding ones of the thin-film transistors, respectively, and disposed on the thin-film transistors; and a lens array including lenses disposed on a second surface of the first substrate opposite to the first surface of the first substrate, wherein the light emitting elements emit light toward the first substrate.