Lenticular Lens Sheet Notch Segmentation for Resin Contraction
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Solution Overview
Problem
Large-scale liquid crystal display devices face issues with measurement stability due to contraction of ultraviolet curing and thermosetting resins used in lenticular lens sheets, leading to distorted lens shapes and compromised display quality as screen sizes increase.
Innovation Solution
A lens sheet design featuring cylindrical lenses isolated from each other with notch sections and linear protrusions or grooves, providing a liquid-repellent characteristic and a multi-layer substrate structure to control resin distribution and prevent malformation, while integrating a color filter on the substrate for improved display quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large-scale liquid crystal display devices use conventional lenticular lens sheets with ultraviolet curing or thermosetting resins, then the lens sheet can be manufactured, but the resin contraction causes lens shape distortion and measurement instability
Solution Approach 1:
The lens sheet is divided into multiple separate lens units, each with an aspect ratio of 5:1 or less. This segmentation prevents the resin contraction that occurs in large-scale continuous lens structures, maintaining lens shape accuracy and measurement stability in large display devices.
Solution Approach 2:
Different regions of the lens sheet have different structural characteristics. Each local lens unit is designed with specific dimensions and aspect ratios optimized for its position, allowing the structure to adapt to local requirements while maintaining overall performance.
2Area of stationary object
If the screen size is increased to expand display devices, then the display area is improved, but the resin contraction becomes more significant causing lens malformation
Solution Approach 1:
Instead of using a single large continuous lens structure that would be prone to contraction and distortion, the lens sheet is segmented into multiple smaller lens units. This allows the display area to be expanded while each individual lens unit maintains its shape accuracy by avoiding excessive resin contraction.
3Device complexity
If cylindrical lenses are formed continuously without isolation, then the lens sheet structure is simpler, but the resin contraction causes the lenses to overlap and deform
Solution Approach 1:
The cylindrical lenses are isolated from each other by dividing the lens sheet into separate lens units with aspect ratios of 5:1 or less. This segmentation prevents the lenses from overlapping due to resin contraction while maintaining a relatively simple overall structure.
Solution Approach 2:
The lens units are designed and positioned in advance with proper spacing and isolation structures before the resin curing process. This preliminary arrangement ensures that even when resin contraction occurs during curing, the lenses remain isolated and maintain their intended shapes.
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 enhances measurement stability and visual properties of the lens sheet, allowing for high-quality, multi-viewpoint image display without sacrificing numerical aperture, even in large screen sizes.
Implementation Method 1
providing a liquid-repellent characteristic and a multi-layer substrate structure to control resin distribution and prevent malformation
Data Source
AI summary
To suppress malshaping in a lenticular lens sheet formed by using ultraviolet curing resin, which is caused due to an increase in the aspect ratio of cylindrical lenses and anisotropy of curing contraction. Notch sections are provided to the cylindrical lenses for sectioning the cylindrical lenses in a pseudo manner in the major axis direction (extending direction) of the cylindrical lenses so as to suppress the anisotropy of the curing contraction of the resin.