Lens Array Gauge Thickness Optimization
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Solution Overview
Problem
The challenge is to reduce the gauge thickness of lens arrays without introducing substantial blurring or other objectionable image artifacts, particularly in high-frequency lenticular sheets where traditional methods result in blurred imagery due to off-focus lenses and severe blurring with multiplexed imagery.
Innovation Solution
Optimizing the gauge thickness and lens parameters of lenslets in a lens array so that each lenslet has a focal point size equal to or varying from the size of image elements by a predetermined amount, allowing for a thinner lenticular sheet with maintained image quality, achieved by determining a scale parameter representative of image element sizes and adjusting lens parameters such as width, refractive index, and radius of curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the gauge thickness of the lenticular sheet is reduced, then manufacturing cost is reduced and applications are broadened, but the lens frequency must be increased which causes blurring and limits printing capabilities
Solution Approach 1:
The patent applies parameter changes by optimizing the lens radius of curvature and other lens parameters based on the gauge thickness and material properties. By adjusting these parameters, the system achieves proper focus at reduced thickness levels without requiring increased lens frequency, thereby maintaining image quality while reducing gauge thickness.
Solution Approach 2:
The patent employs dynamics by making the lens parameters adjustable and optimized for specific thickness conditions. The lens design adapts to the reduced gauge thickness through calculated parameter adjustments, allowing the system to dynamically maintain optimal optical performance across different thickness scenarios.
2Reliability
If the lens frequency is increased to compensate for reduced thickness, then focus is maintained, but printing becomes challenging and waste material increases
Solution Approach 1:
The patent changes the lens parameters (particularly radius of curvature) to optimize focus at reduced thickness without increasing lens frequency. This parameter optimization maintains focus while keeping the lens frequency at levels that are manageable for printing processes, reducing waste and improving manufacturability.
3Ease of manufacture
If traditional lens designs are used with reduced thickness, then manufacturing cost decreases, but off-focus lenses cause substantial blurring
Solution Approach 1:
The patent optimizes lens parameters including radius of curvature based on the reduced gauge thickness and material refractive index. This parameter adjustment ensures that lenses remain properly focused at thinner dimensions, preventing the blurring that would otherwise occur with traditional designs while maintaining cost-effectiveness.
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 approach enables the production of thinner lenticular sheets with high-quality image effects, allowing for more complex visual effects and improved printing capabilities without sacrificing image quality, as the majority of refracted rays intersect with image elements at desired viewing angles, maintaining the sampling effect.
Implementation Method 1
The lens radius of curvature is then determined based on additional parameters such as the refractive index and Abbe number of the polymeric material used, so as to focus incoming light rays substantially at the flat side of the sheet.
Data Source
AI summary
A lens array for imaging image elements in an object plane, and a method of making a lens array. The lens array includes lenslets formed in or on one side of a transparent or translucent material with the image elements disposed on the opposite side, and has a gauge thickness corresponding to the distance from the apex of each lenslet to the object plane. Each lenslet has a set of lens parameters. The gauge thickness and/or at least one lens parameter is or are optimized such that each lenslet has a focal point size in the object plane which is either substantially equal to the size of the image elements in the object plane, or varies from the size of the image elements by a predetermined amount.