Stereoscopic Image Forming Device Groove Mirror Integration
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Solution Overview
Problem
The manufacturing of stereoscopic image forming devices is inefficient due to the need for high-vacuum deposition processes and poor workability in forming metal reflecting surfaces on transparent plates, leading to difficulties in achieving a bright and clear image, especially with uneven plate members and high groove depths causing demolding issues and non-uniform mirror finishing.
Innovation Solution
A method involving press molding, injection molding, or roll molding to create optical control panels with triangular grooves and ridges, followed by selective mirror surface formation on vertical surfaces and integration using a second transparent resin with a lower melting point, allowing for easier demolding and uniform filling of grooves to form band-shaped light reflecting surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal reflecting surfaces are formed on transparent plates using vapor deposition, then reflective quality is improved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The patent replaces expensive, complex vapor deposition processes with a simpler, more economical approach using pre-formed metal reflecting surfaces that are attached to transparent plates. This disposable-like approach eliminates the need for expensive deposition equipment and complex vacuum processes, significantly reducing manufacturing complexity while maintaining reflective quality.
Solution Approach 2:
The metal reflecting surfaces are prepared in advance as separate components before being attached to the transparent plates. This preliminary preparation allows for standardized production of reflective elements that can be easily integrated into the final device, simplifying the overall manufacturing process and reducing on-site complexity.
2Manufacturing precision
If many transparent plates are processed through deposition furnace repeatedly, then metal reflecting surfaces are formed, but manufacturing time increases
Solution Approach 1:
The manufacturing process is divided into separate stages: metal reflecting surfaces are formed on transparent plates in advance as individual components, then these pre-formed elements are assembled into the final stereoscopic image forming device. This segmentation eliminates the need for repeated deposition furnace processing of complete assemblies, dramatically improving manufacturing efficiency.
Solution Approach 2:
Metal reflecting surfaces are formed on transparent plates before assembly into the final device structure. This preliminary formation of reflective surfaces allows for batch processing and eliminates time-consuming repeated deposition cycles, significantly boosting productivity.
3Illumination intensity
If groove heights are increased in uneven plate members, then aspect ratio improves for brighter images, but demolding becomes extremely difficult
Solution Approach 1:
The groove structures with high aspect ratios are formed as separate molded components that are later assembled together. This segmentation allows for optimization of groove depth for image brightness without compromising demolding, as each component can be independently molded with appropriate draft angles and then combined to form the final high-aspect-ratio structure.
Solution Approach 2:
The groove structures are preliminarily formed as complete high-aspect-ratio features in the molded base materials before assembly. This preliminary formation maintains the desired groove heights for image brightness while using molding techniques that facilitate easy demolding of each component.
4Manufacturing precision
If mirror surfaces are applied to side surfaces of parallel grooves, then image quality improves, but product uniformity decreases due to difficulty in uniform mirror-finishing
Solution Approach 1:
The mirror surfaces are applied to groove side surfaces as separate, pre-formed reflective elements rather than attempting uniform mirror-finishing of complex groove structures. This segmentation allows for standardized production of reflective components that ensure consistent image quality and product uniformity.
Solution Approach 2:
Mirror surfaces are preliminarily formed on groove structures before final assembly. This preliminary formation of reflective surfaces on standardized components ensures uniform mirror-finishing quality and consistent product uniformity across all manufactured items.
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 method simplifies the manufacturing process, enhances the aspect ratio of grooves for better image quality, reduces distortion, and achieves a bright and clear stereoscopic image with improved manufacturing efficiency and cost-effectiveness.
Implementation Method 1
filling the grooves with the molten second transparent resin
Implementation Method 2
heating and pressing by flat surfaces
Data Source
Figure 1(A)~1(B)
Figure 2(A)~2(B)
Figure 3(A)~3(B)
AI summary
A method for manufacturing a stereoscopic image forming device includes a first process of molding a pair of molding base materials 22 from a first transparent resin, in each of which a large number of grooves 19 triangular in section each including an inclined surface 17 and a vertical surface 18, and a large number of ridges 20 triangular in section formed by the grooves 19 adjacent to each other, are disposed parallel to each other on one side of a transparent plate member 16, a second process of manufacturing a pair of intermediate base materials 28 by forming mirror surfaces on the vertical surfaces 18 of the respective molding base materials 22, a third process of manufacturing first and second optical control panels 13 and 14 integrated together by making the pair of intermediate base materials 28 face each other so that their vertical surfaces 18 are orthogonal to each other in a plan view, and joining together the intermediate base materials by filling the grooves 19 with a second transparent resin with a lower melting point than a lower melting point of the first transparent resin and a refractive index equal or approximate to a refractive index of the first transparent resin, and the inclined surfaces 17 of the respective molding base materials 22 are formed of a) flat surfaces or b) concave surfaces, uneven surfaces, or polygonal surfaces recessed from the flat surfaces.