Microlens Array Substrate Thermal Warping Prevention
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Solution Overview
Problem
Microlens array substrates tend to warp or deform due to thermal expansion, leading to unevenness and decreased display quality, especially when their thickness increases, and processing variations affect image quality.
Innovation Solution
A microlens array substrate design featuring a light transmitting substrate with a first lens layer and a second lens layer, where a light transmitting layer with a smaller refractive index and coefficient of thermal expansion is interposed between them, allowing for a shorter total film thickness and preventing deformation, while flattening layers and refractive index layers adjust the light path and mitigate processing variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the thickness of the microlens array substrate is increased to improve light transmittance and adjust lens distance, then light transmittance is improved, but the substrate becomes warped or deformed due to thermal expansion
Solution Approach 1:
The patent changes the physical parameters of the intermediate layer by selecting materials with specific refractive indices (lower than lens layers) and coefficients of thermal expansion (lower than lens layers). This parameter selection allows the intermediate layer to counteract thermal expansion effects while maintaining appropriate optical path length for light transmittance.
Solution Approach 2:
The patent employs a composite structure consisting of three distinct layers: lens layers made of one material and an intermediate layer made of a different material with specifically selected properties. This composite approach enables the system to simultaneously achieve good light transmittance through the lens layers and thermal stability through the intermediate layer's compensating properties.
2Length of stationary object
If the thickness of the microlens array substrate is increased to adjust lens distance, then lens distance is adjusted, but processing variation negatively affects quality and image quality deteriorates
Solution Approach 1:
The patent divides the microlens array substrate into three separate layers: first lens layers, an intermediate layer, and second lens layers. This segmentation allows independent optimization and manufacturing of each layer, reducing the cumulative effect of processing variations on the overall lens distance and improving manufacturing precision.
3Stability of the object's composition
If the total film thickness is reduced to prevent warping, then substrate deformation is prevented, but light transmittance may be compromised
Solution Approach 1:
The patent utilizes the refractive index parameter of the intermediate layer (lower than lens layers) to increase light bending effect, which compensates for the reduced physical thickness. This allows the optical path length to be sufficient for light transmittance even when the total film thickness is reduced to prevent warping.
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 design enhances light transmittance and usage efficiency, prevents warping, and maintains display quality by curving incident light and adjusting lens distances without increasing substrate thickness, thereby improving overall display performance.
Implementation Method 1
a ray incident to the light transmitting layer in an oblique direction is refracted to the oblique side, because the refractive index of the light transmitting layer is small. Accordingly, it is possible to significantly curve the incident light.
Implementation Method 2
the light transmitting layer has smaller refractive index and coefficient of thermal expansion than those of the first lens layer and the second lens layer... it is possible to prevent the microlens array substrate from being warped or deformed
Data Source
AI summary
A microlens array substrate includes: a light transmitting substrate in which a first lens surface formed of a concave surface is formed on a substrate surface on one side; a first lens layer which covers the substrate surface on one side and has a refractive index which is different from that of the light transmitting substrate; a light transmitting layer which covers the first lens layer on the opposite side to the light transmitting substrate; and a second lens layer which covers the light transmitting layer on the opposite side to the light transmitting substrate and in which a second lens surface formed of a convex surface is formed on the opposite side to the light transmitting substrate, in which the light transmitting layer has smaller refractive index and coefficient of thermal expansion than those of the first lens layer and the second lens layer.