3D Plastic Cover Lens Assembly for Low-Reflection Vehicle Displays
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Solution Overview
Problem
Vehicle displays with liquid crystal modules are prone to reflecting stray light, hindering driver visibility due to their flat shape, and the high manufacturing cost of three-dimensional glass lenses limits their adoption.
Innovation Solution
A vehicle display using a plastic cover lens with a front film, rear film, and a super retardation film bonded with an optically clear adhesive, combined with a liquid crystal display module, and a panel-front assembly to minimize light reflection and deformation, while reducing manufacturing costs through insert mold labeling and injection-compression molding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a three-dimensional glass lens is used to reduce stray light reflection, then optical performance and visibility are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive glass lenses with plastic lenses that can be manufactured at lower cost through injection molding, making the solution economically viable for mass production while maintaining the three-dimensional curved shape needed to reduce stray light reflection
Solution Approach 2:
The patent changes the material parameter from glass to plastic, enabling the lens to be manufactured through injection molding processes that are more cost-effective and scalable, while preserving the optical functionality through proper surface curvature design
2Ease of manufacture
If a flat liquid crystal display module is used, then manufacturing cost is reduced, but stray light reflection increases and visibility deteriorates
Solution Approach 1:
The patent applies a three-dimensional curved surface to the lens covering the flat liquid crystal display module, which redirects stray light away from the driver's line of sight while maintaining the cost advantages of using a standard flat LCD module
3Ease of manufacture
If a plastic cover lens is used instead of glass, then manufacturing cost is reduced, but durability and optical performance may be compromised
Solution Approach 1:
The patent uses composite material structures including the plastic lens combined with anti-reflection coating layers and anti-fingerprint coating layers, enhancing the durability and optical performance of the plastic lens to match or exceed glass lens performance while maintaining cost advantages
4Ease of manufacture
If the lens surface is made flat, then manufacturing is simpler, but light reflection toward the driver increases
Solution Approach 1:
The patent implements a three-dimensional curved surface on the lens that is integrated into the injection molding process, achieving the light reflection control benefit of curved surfaces while maintaining the manufacturing simplicity and cost effectiveness of mold-based production
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
The solution effectively reduces stray light reflection, enhances optical performance, and lowers manufacturing costs by using a plastic cover lens with a three-dimensional shape, improving driver visibility and reducing gate wash-out issues in the molding process.
Implementation Method 1
a super retardation film (SRF) adhered to a rear surface of the plastic cover lens using an optically clear adhesive (OCA), a liquid crystal display module adhered to a rear surface of the super retardation film using the optically clear adhesive
Implementation Method 2
the front film includes an anti-reflection (AR) coating layer and an anti-fingerprint (AF) coating layer formed at a front surface of the plastic cover lens via vacuum deposition
Implementation Method 3
a plastic cover lens having a three-dimensional shape... a three-dimensional curved front lens are being applied... reduces the effect of the reflected light
Data Source
AI summary
Disclosed is a display for a vehicle including a plastic cover lens including a lens, a front film disposed on a front surface of the lens, and a rear film disposed on a rear surface of the lens, a super retardation film (SRF) adhered to a rear surface of the plastic cover lens using an optically clear adhesive (OCA), a liquid crystal display module adhered to a rear surface of the super retardation film using the optically clear adhesive, a panel-front assembled at the rear of the plastic cover lens, in close contact with and supporting the liquid crystal display module, and preventing deformation of the plastic cover lens, and a rear cover assembled at the rear of the panel-front.