Switchable Lens Filling Channel Design
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Solution Overview
Problem
The manufacturing process of switchable lens systems is hindered by the tunnel-like structure formed by lenticulars, leading to a slower filling process and longer production time, especially for large-sized panels due to the varying gap and shape of the cavities between the substrates.
Innovation Solution
Incorporating a filling channel between the seal line and the periphery of the imaging area to provide a connection between the throughhole and multiple cavities, allowing for improved influx of liquid crystal material and reducing the formation of gas bubbles by ensuring each cavity has a single connection to the filling channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid crystal material is filled into cavities formed by lenticulars using conventional LCD filling process, then the switchable lens system can be manufactured, but the filling process becomes much slower and production time increases
Solution Approach 1:
The invention divides the single throughhole into multiple throughholes distributed around the periphery of the imaging area. Each throughhole serves as an independent filling channel that connects to adjacent cavities. This segmentation of the filling entry points allows simultaneous filling of multiple cavities, dramatically increasing production throughput while ensuring complete filling of all cavities with liquid crystal material
Solution Approach 2:
The invention transitions from a single-point filling approach (one throughhole) to a distributed multi-point filling approach (multiple throughholes around the periphery). This dimensional change in the filling strategy transforms the filling process from a sequential, slow operation to a parallel, efficient operation, resolving the contradiction between filling completeness and production speed
2Productivity
If multiple throughholes are provided around the periphery for filling, then filling speed increases, but device complexity increases
Solution Approach 1:
The seal line is designed to serve multiple functions simultaneously: it seals the imaging area, provides structural support, and incorporates multiple throughholes as integrated filling channels. By making the seal line multi-functional, the invention increases filling speed without adding separate complex components, thus improving productivity while minimizing the increase in device complexity
3Device complexity
If the throughhole is positioned centrally, then the structure is simple, but gas bubbles form and filling is incomplete
Solution Approach 1:
The invention positions throughholes at specific locations around the periphery of the imaging area, close to where cavities are formed. This localized positioning ensures that each throughhole is optimally positioned to fill adjacent cavities completely and minimize gas bubble formation. The non-central, distributed positioning of throughholes improves filling reliability by ensuring complete cavity filling, while the regular peripheral arrangement keeps the structure relatively simple
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 filling process efficiency, reducing production time and improving throughput by facilitating faster and more uniform filling of the liquid crystal material into the cavities, thereby addressing the slow filling issues associated with the lenticular structure.
Implementation Method 1
By applying an electric potential to the liquid material, a change in the effective refractive index of the liquid material can be effectuated which modifies the lens properties of the lenticulars from 3D to 2D mode or vice versa
Implementation Method 2
The lenticulars comprise liquid crystal material. By applying an electric potential to the liquid material, a change in the effective refractive index of the liquid material can be effectuated
Implementation Method 3
A filling channel is located between at least a portion of the periphery of the imaging area and the seal line to provide a connection between the throughhole and multiple ones of the cavities
Data Source
AI summary
Switchable lens systems and methods of manufacturing switchable lens systems are provided. A representative switchable lens system includes an imaging area and a seal line. The imaging area includes a first glass plate, a second glass plate and a lenticular structure. The lenticular structure is arranged in between the first and second glass plates and is provided with a plurality of cavities in between the lenticular structure and one of the first and second glass plates. The seal line surrounds the imaging area at its periphery, and is provided with a throughhole. A filling channel is located between at least a portion of the periphery of the imaging area and the seal line to provide a connection between the throughhole and multiple ones of the cavities.