Microlens Array Alignment for Large-Size Light Field Displays
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Solution Overview
Problem
Existing methods for manufacturing microlens arrays in light field displays face challenges such as high cost, difficulty in large size production, and poor alignment accuracy, particularly with thermal reflow lithography and nanoimprint technologies, leading to misalignment and non-uniformity of lenses.
Innovation Solution
A method involving the formation of a plano-concave lens layer on a substrate, followed by a first planarization layer with higher refractive index, and attaching a display panel to the microlens array using alignment marks, which allows for precise alignment and uniform lens formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If single-point diamond method is used to fabricate MLA template, then manufacturing precision is improved, but cost increases and large size fabrication becomes difficult
Solution Approach 1:
The patent replaces the mechanical single-point diamond drilling method with a photoresist-based lithography approach. A photosensitive resin layer is coated on the substrate, exposed through a mask pattern to form microlens patterns, then developed to create the MLA template. This substitution eliminates the mechanical limitations of single-point drilling, enabling large-scale fabrication while maintaining precision and reducing cost.
2Ease of manufacture
If thermal reflow lithography is used to fabricate MLA template, then cost is reduced and large size is achieved, but close-coupled lenses cannot be fabricated
Solution Approach 1:
The patent changes the key parameter of lens spacing by introducing a controllable gap between adjacent microlens patterns in the mask design. This allows the formation of close-coupled lenses with precise spacing control that thermal reflow alone cannot achieve, while still maintaining the cost and size advantages of lithography-based fabrication.
Solution Approach 2:
The patent performs preliminary patterning of the photosensitive resin layer before the reflow process. The mask pattern is applied and exposed to create precise lens positions and spacing, then the reflow process is used to form the lens shapes. This preliminary action ensures that close-coupled lenses are formed with accurate spacing while benefiting from the low cost and large-size capabilities of thermal reflow lithography.
3Productivity
If conventional alignment methods are used for attaching display panel to microlens array, then alignment accuracy deteriorates, leading to misalignment and non-uniformity
Solution Approach 1:
The patent introduces alignment marks as an intermediary reference system between the display panel and microlens array. These marks are formed on the substrate before attaching the display panel, providing precise registration points that enable accurate alignment during the attachment process. This intermediary reference system eliminates misalignment and non-uniformity while maintaining efficient production.
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 ensures accurate alignment and uniformity of the lens structure, improving light efficiency and reproducibility, especially for large-sized displays.
Implementation Method 1
forming a first planarization layer covering the plano-concave lens layer to form a microlens array, the first planarization layer having a refractive index greater than a refractive index of the plano-concave lens layer
Data Source
AI summary
A method for manufacturing a light field display device and a light field display device are provided, the method includes: forming a plano-concave lens layer on a substrate, and the plano-concave lens layer comprises a plurality of plano-concave lenses arranged in an array and a plurality of alignment marks arranged at preset positions; forming a first planarization layer covering the plano-concave lens layer to form a microlens array, the first planarization layer having a refractive index greater than a refractive index of the plano-concave lens layer; attaching the light-emitting side of the display panel to a side of the microlens array away from the substrate according to the alignment mark.