Optical Module Pixel Area Ratios for Alignment Tolerance
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Solution Overview
Problem
The manufacturing process for optical modules, which involves bonding panels to a prism, often results in misalignment, leading to deteriorated display quality in image display devices due to the varying lifespan of light-emitting materials used in different pixels.
Innovation Solution
An optical module configuration where the second pixel has a larger area than the first pixel, and the third pixel has a smaller area, with specific width ratios to ensure proper alignment and image synthesis, thereby maintaining display quality and extending the lifespan of light-emitting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If panels are bonded to the prism using conventional bonding processes, then the manufacturing process can be completed, but misalignment occurs between the panels and the prism, leading to deteriorated display quality
Solution Approach 1:
The patent applies preliminary action by pre-designing the pixel area ratios to account for potential misalignment. The third pixel area is set to 0.25-0.49 times the first pixel area, and the second pixel area is set to 0.5-1.5 times the first pixel area, which compensates for alignment errors before bonding occurs. This preliminary design ensures that even with misalignment, the optical centers remain sufficiently overlapped to maintain display quality.
2Duration of action of stationary object
If the area of light-emitting pixels is increased to extend lifespan, then the lifespan of light-emitting materials can be extended, but the alignment tolerance during bonding decreases, making misalignment more critical
Solution Approach 1:
The patent applies local quality by creating non-uniform pixel areas across different color channels. Specifically, the third pixel (shorter lifespan material) has a smaller area (0.25-0.49 times the first pixel), while the second pixel (longer lifespan material) has a larger area (0.5-1.5 times the first pixel). This local variation in pixel quality compensates for the different lifespan characteristics and alignment tolerances of different color channels.
Solution Approach 2:
The patent applies parameter changes by modifying the area parameter of different pixels to optimize both lifespan and alignment tolerance. By changing the pixel area ratios (third pixel: 0.25-0.49 times first pixel, second pixel: 0.5-1.5 times first pixel), the system achieves a balance where longer lifespan materials can use larger areas while shorter lifespan materials use smaller areas, thereby extending overall module lifespan while maintaining alignment tolerance.
3Duration of action of stationary object
If the pixel areas are made different to compensate for varying light-emitting material lifespans, then the overall lifespan of the optical module can be extended, but the complexity of the device structure increases
Solution Approach 1:
The patent applies parameter changes by modifying only the area parameter of different pixels while keeping other parameters (such as pixel shape, arrangement, and optical path) consistent. This simple parameter adjustment (area ratios of 0.25-0.49 times and 0.5-1.5 times the first pixel area) achieves lifespan extension without introducing complex structural changes, maintaining relatively simple device architecture.
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 configuration ensures stable image display quality and maintains the lifespan of light-emitting elements by optimizing pixel area ratios and alignment, even with misalignment during the manufacturing process.
Implementation Method 1
a prism configured to synthesize image light emitted from the first electro-optical device and image light emitted from the second electro-optical device
Data Source
AI summary
An optical module includes a first electro-optical device including a first pixel, a second electro-optical device including a second pixel and a third pixel, and a prism. An area of the second pixel is larger than an area of the first pixel, and an area of the third pixel is smaller than the area of the second pixel. A width of the third pixel in a direction corresponding to a first direction in a synthesized image is not less than 0.5 times and less than 1 time a width of the first pixel in the direction corresponding to the first direction, and a width of the third pixel in a direction corresponding to a second direction in the synthesized image is 0.5 times or more and less than 1 time a width of the first pixel in the direction corresponding to the second direction.