Stereoscopic Display Lens Alignment via Dual Adhesive Layers
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Solution Overview
Problem
Existing stereoscopic image display devices face challenges in accurate alignment and joining of lens array substrates and display panels without using alignment keys, which can reduce product reliability and increase costs due to the need for software-based alignment methods.
Innovation Solution
A method involving the formation of grooves on the rear surface of the lens array substrate, deposition of a sticky material layer within these grooves, and the use of a transparent adhesive layer to align and join the display panel and lens array substrate, allowing for physical separation and reattachment for precise alignment without damaging the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If software-based alignment methods are used to join lens array substrates and display panels, then alignment can be achieved without physical alignment keys, but alignment accuracy decreases and product reliability is reduced
Solution Approach 1:
The patent introduces a dual-layer adhesive system where the first adhesive layer with strong adhesive force provides stable bonding, while the second adhesive layer with weak adhesive force enables easy separation and reattachment for alignment adjustment. This intermediary adhesive structure mediates between the need for strong bonding and the need for alignment flexibility, eliminating the need for complex alignment keys while maintaining alignment accuracy.
2Reliability
If the lens array substrate and display panel are joined with strong adhesive force, then product reliability improves, but alignment accuracy decreases due to inability to adjust misalignment
Solution Approach 1:
The patent segments the adhesive function into two distinct layers: the first adhesive layer provides strong bonding force for reliability, while the second adhesive layer provides weak bonding force that allows easy separation and reattachment for alignment adjustment. This segmentation allows each layer to fulfill its specific function without interfering with the other, resolving the contradiction between strong bonding and alignment adjustability.
Solution Approach 2:
The patent applies different adhesive forces at different locations/layers between the lens array substrate and display panel. The first adhesive layer (strong adhesive force) is applied at certain positions to provide stable bonding, while the second adhesive layer (weak adhesive force) is applied at other positions to allow separation and reattachment. This local differentiation of adhesive properties enables both strong overall bonding and localized adjustability for alignment.
3Manufacturing precision
If alignment keys are used to improve alignment accuracy, then manufacturing precision improves, but device complexity and cost increase
Solution Approach 1:
The patent replaces physical alignment keys with an intermediary adhesive-based alignment mechanism. The weak adhesive force of the second adhesive layer acts as an intermediary that allows the lens array substrate to be easily separated and reattached for alignment adjustment, eliminating the need for additional alignment key components while maintaining alignment accuracy through the adhesive layers themselves.
4Manufacturing precision
If the adhesive layer allows easy separation and reattachment for alignment adjustment, then alignment accuracy can be improved, but the adhesive strength and reliability decrease
Solution Approach 1:
The patent segments the adhesive system into two functional layers: the first adhesive layer with strong adhesive force ensures reliable bonding and product reliability, while the second adhesive layer with weak adhesive force enables easy separation and reattachment for alignment adjustment. This segmentation allows the system to exhibit both strong bonding characteristics and easy adjustability depending on which layer is active.
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 enhances the accuracy of alignment and reduces the risk of image distortion by allowing repeated attachment and separation of the panels, minimizing the impact of alignment errors and maintaining the effective display area, thus improving the manufacturing process efficiency.
Implementation Method 1
depositing a sticky material layer in the groove
Implementation Method 2
joining the display panel and the lens array substrate by using the transparent adhesive layer
Implementation Method 3
a lens array that forms a light field by refracting light output from the display panel
Data Source
AI summary
A method of manufacturing a stereoscopic image display device includes forming a groove by etching an edge portion of a rear surface of a lens array substrate, depositing a sticky material layer in the groove, disposed a transparent adhesive layer that differs from the sticky material layer onto a top surface of a display panel, aligning the lens array substrate and the display panel by using a camera, and joining the display panel and the lens array substrate by using the transparent adhesive layer.