Lens Array Integrated Display Panel for Slim HMD Design
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Solution Overview
Problem
Head-mounted displays (HMDs) are limited by the thickness of the eyepiece, which restricts design freedom and requires a bulky structure due to the need for convex lenses, leading to issues like the screen door effect and alignment errors between lenses and sub-pixels.
Innovation Solution
A display device and manufacturing method that eliminate the eyepiece by integrating a lens array directly on the display panel, using sub-pixels to provide view images without the need for an eyepiece, with lenses overlapping sub-pixels and a gap maintaining member to optimize light refraction, allowing for reduced thickness and improved image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If an eyepiece with convex lenses is used to enlarge images for the user, then the user can view a virtual image, but the display device becomes thick and design freedom is reduced
Solution Approach 1:
The patent merges the eyepiece lens array with the display panel by positioning the lens array in direct contact with or very close to the display panel surface. The lens array and display panel are integrated into a single assembly, eliminating the need for a separate eyepiece component and reducing overall device thickness while maintaining the virtual image enlargement function
Solution Approach 2:
The lens array is nested within the display device structure, positioned between the display panel and the user's eye. The lenses are arranged in an array that corresponds to the pixel structure of the display panel, with each lens overlapping one or more sub-pixels, creating a compact nested configuration that reduces the external dimensions of the device
2Reliability
If an eyepiece with convex lenses is used to provide virtual images, then image viewing is enabled, but alignment errors between lenses and sub-pixels occur
Solution Approach 1:
By integrating the lens array with the display panel in a single assembly, the patent eliminates alignment errors between separate components. The lenses and sub-pixels are precisely aligned through the integrated structure, ensuring that each lens correctly overlaps with its corresponding sub-pixels without manufacturing misalignment
Solution Approach 2:
The lens array is designed to self-align with the display panel through the overlapping configuration of lenses and sub-pixels. The structural integration allows the system to maintain precise alignment automatically, reducing the need for complex external alignment mechanisms or procedures
3Reliability
If an eyepiece with convex lenses is used to display images, then virtual images are formed, but the screen door effect is observed
Solution Approach 1:
The patent changes the optical parameters of the system by using a lens array with specific focal lengths and densities that are optimized for the display panel resolution. The lenses are positioned at precise distances from the display panel, and their optical properties are tuned to reduce the visibility of the screen door effect while maintaining virtual image formation
Solution Approach 2:
The lens array is designed with varying local properties, where each lens is specifically configured to overlap with one or more sub-pixels. This local optimization ensures that light from each sub-pixel is correctly refracted through its corresponding lens, reducing the screen door effect by improving the local optical quality at each pixel-lens interface
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
The solution enables a slimmed-down HMD design, reduces the screen door effect, and minimizes alignment errors, providing enhanced image quality and reduced thickness by eliminating the need for an eyepiece and improving light refraction efficiency.
Implementation Method 1
lenses overlapping sub-pixels and a gap maintaining member to optimize light refraction
Data Source
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AI summary
A display device and a method of manufacturing the same are provided. The display device includes a display panel (100) including a series of pixels (P), each pixel (P) including N sub-pixels (RP, GP, BP), where N is an integer of 2 or greater; and a lens array (300) on a surface of the display panel (100), the lens array (300) including a series of lenses (310), wherein each of the lenses (310) overlaps with M sub-pixels (RP, GP, BP), where M is an integer greater than N.