Resin Lens Array Stack for Thermal-Stable Stereoscopic Alignment
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Solution Overview
Problem
Existing stereoscopic display apparatuses face challenges in maintaining high display performance across varying temperature environments, leading to issues such as warpage and detachment of lens arrays from the display panel.
Innovation Solution
A lens array unit comprising a resin lens array with a thermal expansion coefficient similar to glass, combined with a buffer layer having a higher thermal expansion coefficient, is used to maintain accurate pixel-lens alignment and prevent warpage or detachment, even with temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a resin lens array is used in the stereoscopic display apparatus, then the manufacturing cost and weight are reduced, but the lens array becomes susceptible to thermal expansion and deformation at high temperatures, compromising display performance
Solution Approach 1:
The patent modifies the thermal expansion characteristics of the resin lens array by controlling its coefficient of thermal expansion to be 50-150 ppm/°C, which is higher than glass but carefully selected to match the expansion characteristics of the adhesive layer. This parameter optimization allows the resin lens array to maintain dimensional stability during temperature changes while preserving the cost and weight advantages of using resin instead of glass
Solution Approach 2:
The patent employs a composite structure consisting of the resin lens array, adhesive layer, and backlight unit with specifically selected materials. The adhesive layer is chosen to have a coefficient of thermal expansion of 30-70 ppm/°C, creating a composite system where the thermal expansion of different layers is balanced. This composite approach allows the resin lens array to be used while maintaining overall structural stability and display performance across temperature variations
2Stability of the object's composition
If the lens array is firmly adhered to the display panel, then alignment stability is improved, but thermal stress during temperature changes causes warpage and detachment
Solution Approach 1:
The patent deliberately selects materials with specific coefficient of thermal expansion values to create a matched thermal expansion system. The adhesive layer's coefficient (30-70 ppm/°C) is chosen to be between that of the resin lens array (50-150 ppm/°C) and the backlight unit (20-50 ppm/°C), ensuring that all components expand and contract at compatible rates during temperature changes. This thermal expansion matching prevents differential stress accumulation that would otherwise cause warpage or detachment, while still maintaining firm adhesion for alignment stability
3Reliability
If glass is used for the lens array, then thermal stability is improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent changes the thermal expansion parameter of the resin lens array to fall within the specific range of 50-150 ppm/°C, which provides adequate thermal stability for display applications. While this does not match glass exactly, it is sufficient to prevent excessive warpage when combined with the matched adhesive layer, thereby achieving acceptable thermal stability without the weight penalty of glass
Solution Approach 2:
The patent creates a composite assembly of resin lens array, adhesive layer, and backlight unit where the combined thermal characteristics provide sufficient stability. The resin lens array itself remains lightweight, and the composite structure's overall thermal expansion is balanced through material selection, achieving a compromise between the light weight of resin and the thermal stability of glass
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 ensures high display performance by maintaining precise alignment of display pixels and lenses across temperature variations, preventing warpage and detachment, thus ensuring clear stereoscopic viewing.
Implementation Method 1
The resin lens array has a first coefficient of thermal expansion within a first range that includes a coefficient of thermal expansion of glass. The buffer layer has a second coefficient of thermal expansion higher than the first coefficient of thermal expansion.
Data Source
AI summary
A stereoscopic display apparatus having high display performance independently of a temperature environment is provided. A stereoscopic display apparatus of the present disclosure includes a display panel and a lens array unit. The display panel includes a display surface in which multiple display pixels are arranged. The lens array unit is disposed to be opposed to the display surface of the display panel. The lens array unit includes a stacked structure. The stacked structure includes a resin lens array and a buffer layer. The resin lens array has a first coefficient of thermal expansion within a first range that includes a coefficient of thermal expansion of glass. The buffer layer has a second coefficient of thermal expansion higher than the first coefficient of thermal expansion.