Stacked Microlens Substrate Layout for Lower Display Crosstalk
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing microlens substrates in display devices suffer from light crosstalk due to gaps between adjacent microlenses, which can lead to reduced light output efficiency and process failures during thermal reflow processes.
Innovation Solution
A microlens substrate design featuring a first lens pattern with first microlenses and a second lens pattern with second microlenses, where the orthographic projection of at least one second microlens is located between two adjacent first microlenses, reducing the gap between adjacent microlenses and minimizing contact issues during thermal reflow, thereby reducing light crosstalk and eliminating the need for a black matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gaps between adjacent microlenses are increased to prevent contact during thermal reflow, then manufacturing reliability is improved, but light crosstalk increases
Solution Approach 1:
The patent introduces a vertical stacking dimension by placing a second lens pattern on a side of the first planarization layer, away from the first microlenses. This multi-layer arrangement allows the horizontal gap between adjacent microlenses in the same layer to be larger (preventing contact during reflow) while the vertical stacking and offset positioning of the second lens pattern maintain optical isolation and reduce crosstalk through dimensional separation.
Solution Approach 2:
The microlens array is segmented into two distinct lens patterns (first and second) positioned at different vertical levels. Each lens pattern can be independently optimized, and the segmentation allows for larger horizontal spacing within each layer while maintaining overall optical performance through the combined multi-layer structure.
2Object-generated harmful factors
If a black matrix is added to reduce light crosstalk, then light crosstalk is reduced, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent extracts and removes the black matrix component from the conventional microlens substrate structure. Instead of using a black matrix to block light between lenses, the invention achieves light isolation through the spatial arrangement of microlenses with larger gaps and the vertical stacking of lens patterns, thereby eliminating the need for additional light-blocking materials and simplifying the overall device structure.
3Reliability
If microlenses are arranged with larger gaps to prevent contact during thermal reflow, then manufacturing reliability is improved, but light output efficiency decreases
Solution Approach 1:
By transitioning from a single-layer to a multi-layer vertical stacking architecture, the patent allows each layer to have larger horizontal gaps for manufacturing reliability while the vertical arrangement and offset positioning ensure that light paths between adjacent lenses in the same layer remain isolated, thereby maintaining light output efficiency despite larger intra-layer spacing.
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 design effectively reduces light crosstalk and prevents process failures by optimizing the gap between microlenses, enhancing light output efficiency and manufacturing reliability.
Implementation Method 1
a first lens pattern disposed on a side of the base and including a plurality of first microlenses distributed at intervals
Implementation Method 2
a first planarization layer covering light exiting surfaces of the plurality of first microlenses, where the light exiting surfaces of the plurality of first microlenses are respectively outward convex surfaces, and a refractive index of the first planarization layer is less than that of each of the plurality of first microlenses
Data Source
AI summary
A microlens substrate, a display device and a method for manufacturing a microlens substrate are provided. The microlens substrate includes: a base; a first lens pattern disposed on a side of the base and including a plurality of first microlenses distributed at intervals; a second lens pattern disposed on a side of the first lens pattern and including a plurality of second microlenses distributed at intervals, where an orthographic projection of at least one of the plurality of second microlens on the base is located between two orthographic projections of two adjacent first microlenses on the base.