Optical Lens Deformation Prevention in Display Apparatus
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Solution Overview
Problem
The reflow process used in forming optical lenses for display apparatus can cause shape deformation, leading to image quality degradation due to contact between adjacent optical lenses.
Innovation Solution
A display apparatus design featuring a bank insulating layer, encapsulation unit, black matrix, optical insulating layer, touch electrodes, and lens barriers, where the lens barriers surround and separate optical lenses to prevent deformation during the reflow process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the reflow process is used to form optical lenses, then the manufacturing efficiency is improved, but the shape precision of optical lenses deteriorates due to contact and deformation
Solution Approach 1:
The patent divides the formation process of optical lenses into two independent stages: first forming a lens pattern through reflow process, then forming the final optical lens through a separate molding process. This segmentation allows the reflow process to create the basic pattern without requiring high precision, while the subsequent molding process achieves the final shape precision without causing lens contact deformation.
Solution Approach 2:
The patent performs the lens pattern formation through reflow process as a preliminary action before the final lens molding. This preliminary reflow step creates the basic lens pattern and positioning, which then serves as a template for the subsequent precise molding process, separating the pattern creation from the precision shaping.
2Ease of manufacture
If optical lenses are formed by reflow process, then the manufacturing process is simplified, but image quality deteriorates due to lens shape deformation
Solution Approach 1:
The manufacturing process is segmented into two distinct steps: reflow process for pattern formation and molding process for precision lens formation. This maintains the simplicity advantage of reflow while adding a precision step that prevents image quality deterioration.
Solution Approach 2:
The patent introduces an intermediate lens pattern as a mediator between the reflow process and the final optical lens. This intermediate pattern serves as a template that captures the benefits of reflow simplicity while allowing subsequent precise molding to achieve the required optical quality.
3Ease of manufacture
If adjacent optical lenses are allowed to contact during reflow, then the manufacturing process is easier, but the reliability of image display deteriorates due to shape distortion
Solution Approach 1:
The patent separates the lens formation into pattern creation (where contact is acceptable) and final shaping (where contact must be prevented). This segmentation allows easy manufacturing in the first stage while ensuring reliability in the second stage through controlled molding processes.
Solution Approach 2:
The reflow process is performed as a preliminary action that creates the lens pattern without requiring prevention of contact, while the subsequent molding process is the main action that forms the final lenses with precise control to prevent contact and ensure image display reliability.
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
Prevents optical lens deformation and maintains image quality by ensuring that optical lenses do not contact each other during the reflow process, thereby avoiding shape deviations and luminance distortions.
Implementation Method 1
The optical lens may concentrate the light emitted from the light-emitting device
Data Source
AI summary
A display apparatus includes a light-emitting device and an optical lens are stacked on an emission area of a device substrate. A black matrix and a touch electrode may be disposed on a non-emission area of the device substrate. An encapsulation unit covering the light-emitting device and an optical insulating layer covering the black matrix may be disposed on the emission area and the non-emission area of the device substrate. The touch electrode and the optical lens may be disposed on the optical insulating layer. A lens barrier may be disposed on the optical insulating layer. The optical lens may be surrounded by the lens barrier. Thus, in the display apparatus, a deform of the optical lens due to a reflow process may be prevented. Therefore, in the display apparatus, decreasing the quality of the image due to a process of forming the optical lens may be prevented.