Patterned Retarder Manufacturing via Segmented Exposure Energy
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Solution Overview
Problem
Current methods for manufacturing patterned retarders used in three-dimensional display devices are inefficient, leading to higher production costs and reduced display quality, particularly in achieving optimal polarization patterns for 3D image representation.
Innovation Solution
A method involving partial and whole exposure processes with specific exposure energies is used to define and form first and second retarder regions with perpendicular polarization patterns on the patterned retarder, allowing for reduced exposure energy usage and improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manufacturing methods are used for patterned retarders, then production costs are high and manufacturing efficiency is low, but the patent applies partial and whole exposure processes to reduce exposure energy and improve efficiency
Solution Approach 1:
The patent divides the exposure process into two distinct segments: a partial exposure process that exposes only specific regions (first and second retarder regions) with first and second exposure energies respectively, and a whole exposure process that exposes the entire patterned retarder with a third exposure energy. This segmentation allows different regions to receive tailored exposure energies, optimizing the formation of polarization patterns while reducing total exposure energy consumption and improving manufacturing efficiency.
Solution Approach 2:
The patent applies different exposure energies to different regions of the patterned retarder. The first retarder region receives a first exposure energy, the second retarder region receives a second exposure energy, and the entire retarder receives a third exposure energy in the whole exposure process. This local quality approach ensures that each region achieves optimal polarization pattern formation with appropriate exposure energy, avoiding uniform over-exposure or under-exposure.
2Loss of time
If conventional manufacturing methods are used, then manufacturing time is long, but the patent uses multi-stage exposure processes to reduce manufacturing time
Solution Approach 1:
The patent performs preliminary partial exposure processes before the final whole exposure process. In the partial exposure process, specific retarder regions are pre-exposed with appropriate energies to initiate polarization pattern formation. This preliminary action allows the subsequent whole exposure process to complete the pattern formation more efficiently, reducing total manufacturing time despite adding a process step.
Solution Approach 2:
The patent employs periodic exposure actions with different parameters: first exposure energy for the first retarder region, second exposure energy for the second retarder region, and third exposure energy for the entire patterned retarder. This periodic application of exposure energy in controlled stages optimizes the overall exposure efficiency and reduces manufacturing time.
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 enables the production of patterned retarders with lower exposure energy requirements, reducing manufacturing time and costs while maintaining high display quality by effectively separating left and right eye images for 3D representation.
Implementation Method 1
forming a first polarization pattern at the first retarder region by a partial exposure process having a first exposure energy; and forming a second polarization pattern at the second retarder region by whole exposure process having a second exposure energy
Data Source
AI summary
The present disclosure relates to a method for manufacturing the patterned retarder used in the three-dimensional display device. The present disclosure suggests a method for manufacturing a patterned retarder comprising: defining a first retarder region and a second retarder region in the patterned retarder; forming a first polarization pattern at the first retarder region by a partial exposure process having a first exposure energy; and forming a second polarization pattern at the second retarder region by whole exposure process having a second exposure energy. By manufacturing the patterned retarder with lower exposure energy, it is possible to reduce the whole manufacturing takt time, so that the production yield can be enhanced and the production cost can be reduced.