Naked-Eye 3D Device Micro-Lens Alignment Spacer Layer
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Solution Overview
Problem
Existing methods for manufacturing naked-eye 3D devices suffer from poor accuracy and repeatability in aligning micro-lenses with pixel islands, leading to suboptimal 3D display effects due to excessive distance between alignment marks and the plane for forming micro-lens arrays.
Innovation Solution
A method involving the formation of a spacer layer with alignment marks between the spacer layer and the display module, allowing the photolithography apparatus to directly align micro-lenses with pixel islands, reducing the distance for accurate focus exposure and achieving high-precision alignment, thereby improving the stereoscopic effect of the 3D device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If alignment marks within the display module are used as reference for forming the micro-lens array, then the manufacturing process can be simplified, but the distance between the alignment mark and the plane to form the micro-lens array becomes excessive, leading to poor alignment accuracy
Solution Approach 1:
The patent introduces a spacer layer as an intermediary component between the display module and the micro-lens array. This spacer layer carries alignment marks that are positioned close to the micro-lens formation plane, enabling the photolithography apparatus to accurately locate and align with the pixel islands without being hindered by excessive distance. The spacer layer thus mediates between the display module and the micro-lens array, solving the alignment accuracy problem while maintaining manufacturing simplicity.
Solution Approach 2:
The patent transitions from using alignment marks only within the display module plane to introducing alignment marks on a separate spacer layer in a different spatial dimension. This dimensional change allows the alignment marks to be positioned optimally close to the micro-lens formation plane, improving the photolithography apparatus's ability to perform focus exposure and achieve high-precision alignment between micro-lenses and pixel islands.
2Adaptability or versatility
If multiple layers of spacer layers are formed to adjust focal length, then the degree of freedom and application range are improved, but the device structure becomes more complex
Solution Approach 1:
The patent makes the optical system adjustable by allowing the focal length to be dynamically changed through the number of spacer layers. By forming 1 to N layers of spacer layers, the system can adapt to different focal length requirements for various application scenarios. This dynamic configurability enables the same manufacturing method to produce naked-eye 3D devices with different optical characteristics, improving versatility without requiring completely different manufacturing processes.
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 method enhances the alignment accuracy of micro-lenses and pixel islands, enabling ultra-multi-viewpoint parallax 3D displays and improving the stereoscopic effect of naked-eye 3D devices by ensuring precise alignment without relying on alignment marks within the display module.
Implementation Method 1
when forming the micro-lens array, the photolithography apparatus can directly form the micro-lens array according to the alignment mark between the spacer layer and the display module
Data Source
AI summary
Embodiments of the present application disclose a method for manufacturing a naked-eye 3D device and a naked-eye 3D device. The method includes: forming a display module including a plurality of pixel islands; forming a spacer layer on the display module; and forming a micro-lens array on the spacer layer, wherein the spacer layer is formed to have a thickness such that the plurality of pixel islands are located at a focal plane of the micro-lens array. The method further includes: forming an alignment mark between the spacer layer and the display module, wherein the alignment mark is used for, when forming the micro-lens array, aligning each micro-lens in the micro-lens array with one of the plurality of pixel islands.