An ultra-high resolution display screen based on ordered porous material frame confined pixels and a manufacturing method thereof

Abstract

The application provides an ultra-high resolution display screen based on ordered porous material frame limited pixels and a manufacturing method thereof. A pixel frame of the display screen is an ordered porous material grown on a substrate, and a sidewall of the ordered porous material is a high reflectivity or high light absorption material. The ultra-high resolution display screen can be divided into a photoluminescence type and an electroluminescence type. If the ultra-high resolution display screen is the electroluminescence type, a monomer multi-primary light source matched with a pore diameter or smaller than the pore diameter is placed or grown at the bottom of each ordered porous material channel, so that each monomer light source is a display pixel or a sub-pixel of the ultra-high resolution display screen. The pixel uses the ordered porous material as a frame, and a sealing material is used for encapsulation at the top of the frame to form an electroluminescence structure. If the ultra-high resolution display screen is the photoluminescence type, a monomer light source placed or grown at the bottom of the channel can be used as an excitation light source, a fluorescent material color conversion layer is embedded in a light emission direction of the monomer light source in the channel, and finally, an encapsulation layer is covered to form a photoluminescence structure.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of photoelectric display, and particularly relates to an ultra-high resolution display screen based on ordered porous material framework confined pixels and a manufacturing method thereof. BACKGROUND

[0002] In recent years, with the rapid growth of technology and the increase of market demand, the development of near-eye display, AR / VR and wearable devices is promoted, which makes it an urgent technical goal to realize miniaturization and ultra-high resolution display. However, to realize an ultra-high resolution display screen, the first problem to be solved is the full-color problem of the display screen. Compared with the huge transfer technology which is difficult in technology, the scheme of taking monochrome Micro-LED as a single light source and quantum dots as a color conversion layer has higher yield and potential mass production feasibility.

[0003] Quantum dots (QD) are currently popular nanocrystalline materials. Due to their adjustable emission wavelength, high emission efficiency, excellent color conversion performance and unique quantum confinement effect, they have become a new star in the display field. Although quantum dots have many advantages, many problems still need to be overcome in order to truly use quantum dots to replace traditional fluorescent materials, such as the environmental stability of quantum dots.

[0004] Ordered porous materials are a kind of nanomaterials with unique porous structure. According to the pore size, they can be divided into microporous (<2 nm), mesoporous (2 nm-50 nm) and macroporous (>50 nm). They have the characteristics of high specific surface area and ordered pore structure. At present, there are a large number of related researches on the combination of quantum dots and ordered porous materials to protect quantum dots. Because the ordered porous material structure is dense and strong, the contact probability of quantum dots embedded or intracrystallized in the pore channel with the environment is greatly reduced, and the environmental stability is improved. The addition of ordered porous materials makes the dispersion of quantum dots better, avoiding the agglomeration of quantum dots. SUMMARY

[0005] In order to overcome the defects and deficiencies existing in the prior art, the purpose of the present application is to provide an ultra-high resolution display screen based on ordered porous material framework confined pixels. This display screen structure can improve the light-emitting efficiency of LED, OLED or QLED, and at the same time effectively reduce the crosstalk between LED, OLED or QLED array pixels, so that the display screen has low power, high efficiency light source and higher quality image.

[0006] In order to realize the super high resolution display screen, the application extends the quantum dot ordered pore composite material, proposes an ordered pore material layer structure design which is vertically grown on the substrate and takes high reflectivity or high light absorption material as the skeleton, and takes the ordered pore material layer as the pixel layer, and each pore channel corresponds to a display pixel or sub-pixel. The application proposes a full colorization and a non-crosstalk display scheme suitable for the micron to picometer level LED, OLED or QLED and other light-induced or electric-induced display screens, and provides higher density and higher quality images for near-eye display, projection display and other super high resolution displays.

[0007] In the application scheme, the pixel frame of the display screen is the ordered pore material grown on the substrate, and the sidewall is the high reflectivity or high light absorption material. The sidewall structure of the ordered pore can be a vertical structure, or can be prepared into an inclined sidewall through etching or laser processing technology. The super high resolution display screen can be divided into a light-induced luminescence type and an electric-induced luminescence type. If it is electric-induced luminescence, a single monochromatic light source which is matched with the aperture or smaller than the aperture is placed or grown at the bottom of each ordered pore material channel, so that each single light source is a display pixel or sub-pixel of the super high resolution display screen. The pixel takes the ordered pore material as the frame, and the frame top is packaged with a sealing material to form an electric-induced luminescence structure. If it is light-induced luminescence, a single light source placed or grown at the bottom of the channel can be used as an excitation light source, a fluorescent material color conversion layer is embedded in the light emission direction of the single light source in the channel, and finally a packaging layer is covered to form a light-induced luminescence structure.

[0008] If the light emission needs to be processed, an optical layer can be added on the packaging layer. If the ordered pore material frame is composed of high reflectivity material, the light emitted by the single light source or the light emitted after the excitation of the color conversion material is emitted from the top cross section of the ordered pore material channel, and part of the light beams with large emission angles are totally reflected by the high reflectivity pixel frame sidewall for many times, and finally they are also gradually aggregated and emitted from the top cross section, thereby improving the light emission efficiency of the single pixel and the anti-crosstalk ability. If the ordered pore material frame is composed of high absorption material, the light which cannot be emitted from the channel cross section can also be absorbed by the high light absorption pixel frame sidewall, so as to avoid the inter-pixel crosstalk.

[0009] The application specifically adopts the following technical scheme:

[0010] A super high resolution display screen based on the ordered pore material frame limited pixel takes the ordered pore material grown on the substrate as the pixel frame of the display screen, and sets a light source at the bottom of the channel, so that the light source separated by the ordered pore material is a display pixel or sub-pixel of the super high resolution display screen; and forms an electric-induced luminescence structure or a light-induced luminescence structure on this basis.

[0011] Further, the substrate is provided with an isolation layer on the light source in the channel to encapsulate the top of the ordered porous material, and the contact electrode of the light source is pre-plated on the substrate at the bottom of the ordered porous material.

[0012] Further, the pixel frame is an ordered porous material layer with a vertical or inclined sidewall grown on the substrate, the single pixel frame is symmetrical along the central axis, and the channel direction or the central axis direction of the pixel frame is perpendicular to the substrate; the ordered porous material adopts a high reflectivity or high absorption material to avoid crosstalk between pixels.

[0013] Further, the light source adopts a single monochromatic light source confined in the ordered porous material channel to achieve full-color display or controllable monochromatic display, by placing or growing a single monochromatic light source with a size matching or smaller than the aperture at the bottom of each ordered porous material channel, so that each single monochromatic light source is a display pixel or sub-pixel of the super-high resolution display screen; or a full-surface light source at the bottom of the ordered porous material substrate, at this time the frame acts as an isolated pixel to achieve panel monochromatic display.

[0014] Further, when using an electroluminescent structure, a single monochromatic light source is used as a display pixel or sub-pixel of the panel, and when using a photoluminescent structure, a light source is used as an excitation light source of the nanophosphor color conversion layer, and each primary color light is generated by the excitation light source and the nanophosphor color conversion layer excited by the excitation light source.

[0015] Further, the isolation layer is provided with one or more of a diffusion plate layer, a metasurface layer, and a polarizing plate layer.

[0016] Based on the above design, it can be seen that the display screen provided by the present application includes the following typical structures:

[0017] An ordered porous material frame layer, the frame is an ordered porous material layer with a vertical or inclined sidewall grown on the substrate, and the single pixel frame is symmetrical along the central axis, and the channel direction or the central axis direction of the pixel frame is perpendicular to the substrate.

[0018] A single light source placed or grown in the channel of the frame.

[0019] An isolation layer covering the top of the channel and other optical layers with special functions.

[0020] If it is a photoluminescent type panel, a nanophosphor color conversion layer needs to be prepared between the single light source and the isolation layer.

[0021] As a preferred design, the following description can be referred to:

[0022] The ordered porous material framework is an ordered porous material vertically or obliquely grown on a substrate, wherein the ordered porous material can be selected as a high reflectivity material including but not limited to titanium dioxide, aluminum oxide, silver oxide, etc., or a high light absorption material including but not limited to carbon black, etc., the inner diameter of the pore channel can be divided into ordered mesoporous material, ordered mesoporous material and ordered macroporous material, the overall inner diameter is in the range of 0.01 nm-1 μm, and the pore channel is densely arranged and ordered, and the pore channel shape is not limited to circular, but can be square, triangular, rhombic, etc. When the pixel framework selects a high reflectivity material, the light that cannot be emitted from the cross section at a large angle in the pore channel can be polymerized, and the light can be emitted from the top cross section of the pore channel through multiple total reflections, which can greatly improve the quantum dot radiation recombination rate and improve the light emission efficiency; when the pixel framework selects a high absorption material, the light that cannot be emitted from the cross section of the pore channel can be absorbed, and the light can be used as a black matrix. Both can avoid the crosstalk problem between adjacent pixels during display. In full-color display, the pixel arrangement mode can include but is not limited to standard primary colors RGB, Pentile, Delta, diamond arrangement, etc. In monochrome display, the side wall framework can act as a pixel isolation.

[0023] One or more single light sources are placed or grown in each pore channel of the ordered porous material framework, the size of the single light source is equal to or smaller than the size of the pore channel, and the oblique side wall pore channel can place a trapezoidal structure single light source matched with the side wall pore channel, which is helpful for light collection and collimation. The contact electrode of the single light source is pre-plated on the substrate at the bottom of the ordered porous material, so as to be connected with the driving circuit later. The single light source includes but is not limited to LED (including Mini-LED, Micro-LED and Nano-LED, etc.), OLED (including Mini-OLED and Micro-OLED, etc.) and QLED, etc.

[0024] The isolation layer material includes but is not limited to sealing materials such as organic silicon, which is used for packaging the top of the ordered porous material, and can protect the structure of the ordered porous material and improve the stability of the structure. Other functional layers with special functions include but are not limited to a diffusion plate layer with light homogenization function, a metasurface layer with light collimation function, and a polarizer layer with polarization characteristics, etc.

[0025] The nano-fluorescent material color conversion layer is formed on the surface of the bottom light source by in-situ growth, inkjet printing or evaporation, etc., and can fill the pore channel and emit light by exciting the bottom light source. The nano-fluorescent material includes but is not limited to quantum dot material, organic dye molecule and phosphor, etc.

[0026] The bottom light source can be a single light source confined in the pore channel of the ordered porous material, or can be a full-surface light source at the bottom of the ordered porous material substrate. If it is a single light source, the display panel can realize full-color display or controllable monochromatic display, and if it is a surface light source, the frame acts as a pixel isolation function to realize monochromatic display of the panel.

[0027] The display type can be divided into electroluminescent type panel and photoluminescent type panel. If it is a photoluminescent type panel, the single light source acts as an excitation light source of the nanophosphor color conversion layer, which can be a blue light or ultraviolet light wavelength light source, and each primary color light is generated by the excitation light source and the quantum dot color conversion layer excited thereby. For the electroluminescent type panel, the single multi-primary color light source acts as a display pixel or sub-pixel of the panel.

[0028] The pixel color is determined by the single light source in the pore channel, and corresponding primary color light sources can be prepared in the pore channel according to the arrangement requirements of each primary color pixel, or multi-primary color pixels can be expanded to realize a wider color gamut range.

[0029] Further, in the preparation process, first, a single multi-primary color light source is placed or grown in the growth ordered porous material frame, which acts as a sub-pixel or display pixel, then a sealing layer is prepared on the single light source in the pore channel using a sealing solvent, and finally bonded with a driving substrate to realize panel preparation. If it is a photoluminescent type panel, a nanophosphor color conversion layer needs to be prepared on the single light source. If light output needs to be processed, an optical layer with other functions can be added on the sealing layer.

[0030] Preparation is carried out by the following steps:

[0031] Step 1: Provide a wafer or glass substrate with a clean surface, and grow an ordered porous material frame perpendicular to the substrate on the surface of the substrate by template self-assembly method;

[0032] Step 2: Place or grow a light source structure in each pore channel of the ordered porous material frame substrate perpendicular to the substrate from bottom to top;

[0033] Step 3: Encapsulate by preparing an isolation layer;

[0034] Step 4: Bond the panel with a driving substrate to form a display screen.

[0035] Further, when a photoluminescent structure is used, the preparation process of a nanophosphor color conversion layer is further included between step 2 and step 3;

[0036] The color conversion layer material adopts quantum dot material, organic dye molecule or phosphor; if quantum dot color conversion material is adopted, in-situ growth by ion exchange, room temperature supersaturation crystallization, ultrasonic synthesis, anhydrous toluene assisted method, thermal injection method is used to grow in the hole, and based on the limitation of ordered porous material, the quantum dot particle size growth is controllable, and the quantum dot fills the hole of the ordered porous material; or the quantum dot matched with the pore size of the ordered porous material is prepared in advance, and the quantum dot is assembled into the hole of the corresponding ordered porous material in the way of wet mixing, evaporation or PDMS template transfer.

[0037] Further, in step 1, the hole shape, hole inner diameter size and hole side wall inclination are adjusted by one of ICP etching, laser beam etching, electron beam exposure and ion beam exposure methods;

[0038] In step 2, the light source adopts the placement or growth method of monomer light source, if the monomer light source is prepared first and then placed in the ordered porous material frame, the monomer light source stripped from the outer substrate is moved into the ordered porous material frame by fluid self-assembly or transfer technology; if the scheme of growing directly in the ordered porous material frame is adopted, the monomer light source functional layer is grown layer by layer by MOCVD, and the ordered porous material frame plays a isolation role.

[0039] Further, when preparing a photoluminescence type panel, the pixel size of different colors is the same, or the pixel size is differentiated by changing the hole inner diameter; when the hole inner diameter is the same, each primary color nanophosphor material is filled into the hole of the ordered porous material by inkjet printing technology, and due to the limitation of the ordered porous material frame, under the condition that the filling height and the light emitting area size are equal, the luminous intensity of the light emitting pixels of different colors is balanced by controlling the concentration of each primary color nanophosphor material; when the hole inner diameter needs to be adjusted, the hole is etched to change the hole shape, the color conversion layer is limited by the hole, the particle size is controlled to realize the control of different light emitting colors or the halogen element is changed to change the color of the color conversion layer; or by wet mixing, the prepared color conversion material is filled into the hole, and due to the different particle sizes of nanophosphor materials of different colors, the matched hole inner diameter is also different, so the single color wet filling method is used according to the order of light emitting color to realize the sequential filling of the hole from large to small;

[0040] In the preparation of full-color electroluminescent panel, the prepared multi-primary LED or QLED monomer is positioned and attached, imprinted and transferred, and the curing step is repeated to realize the full-color pixel arrangement of the monomer light source in the channel by PDMS transfer printing, or the ordered porous material isolation layer is grown between the ITO anode and the transparent cathode electrode of the OLED, the ITO electrode layer is sputtered and grown on the substrate, the ITO is etched and filled with isolation columns, the ordered porous material frame is grown, the nano fluorescent material is filled, the transparent cathode electrode layer is grown, the transparent electrode is etched and filled with a cathode isolation layer, and the panel is packaged; wherein the nano fluorescent material is placed in the channel of the ordered porous material by inkjet printing or evaporation technology, and the full-color pixel arrangement of the panel is realized by changing the nano fluorescent material in the channel.

[0041] For the light emission regulation of the monomer light source, the regulation of the overall light intensity and color balance is realized by regulating the excitation current of each color monomer light source, or the size of the display pixel is changed to realize the regulation of the light emission by etching the channel to form channel structures with different inner diameters.

[0042] Further, other functional layers, including but not limited to, a diffusion plate layer with approximately uniform scattering performance prepared by coating, texture design and processing steps, a metasurface layer with light collimation function prepared by electron beam evaporation, chemical plating, magnetron sputtering and other processing methods, and a polarizing plate layer with light filtering effect prepared by chemical vapor deposition, physical vapor deposition, hot pressing, stretching and other processes.

[0043] Compared with the prior art, the super-high resolution display screen structure based on the ordered porous material frame limiting pixel of the preferred embodiment of the present application provides a solution for the full-color, non-crosstalk display of micrometer to picometer level LED, OLED or QLED light emitting devices, and can provide higher density and higher quality images for near-eye display, projection display and other super-high resolution displays. BRIEF DESCRIPTION OF DRAWINGS

[0044] The present application will be further described in detail below with reference to the accompanying drawings and specific embodiments:

[0045] Figure 1 is a schematic diagram of the super-high resolution display screen based on the ordered porous material frame limiting pixel of the embodiment of the present application;

[0046] Figure 2 is a top view RGB pixel distribution diagram of the super-high resolution display screen based on the ordered porous material frame limiting pixel of the embodiment of the present application;

[0047] Figure 3 is a sectional view of the vertical growth structure of the super-high resolution display screen based on the ordered porous material frame limiting pixel of the embodiment of the present application;

[0048] Figure 4 is a structural diagram of LED or OLED light source adapted to the inclined ordered porous material side wall structure of the super-high resolution display screen based on the ordered porous material framework confined pixels according to the embodiment of the present application;

[0049] Figure 5 is a structural diagram of LED or OLED light source adapted to the vertical ordered porous material side wall structure of the super-high resolution display screen based on the ordered porous material framework confined pixels according to the embodiment of the present application;

[0050] Figure 6 is a sectional view of the inclined growth structure of the super-high resolution display screen based on the ordered porous material framework confined pixels according to the embodiment of the present application;

[0051] Figure 7 is a fluid self-assembly schematic diagram of the light source of the super-high resolution display screen based on the ordered porous material framework confined pixels according to the embodiment of the present application;

[0052] Figure 8 is a preparation process flow of an OLED structure type panel of the super-high resolution display screen based on the ordered porous material framework confined pixels according to the embodiment of the present application.

[0053] Figure 1 In the figure, 101 is a substrate; 102 is an ordered porous material layer; 103 is an isolation layer; 104 is other special functional layer;

[0054] Figure 2 In the figure, 201 is an ordered porous material framework; 202 is an R sub-pixel light emitting point; 203 is a G sub-pixel light emitting point; 204 is a B sub-pixel light emitting point;

[0055] Figure 3 In the figure, 301 is RGB emitting light after color conversion from the ordered porous material channel; 302 is a special functional layer grown on the isolation layer; 303 is an isolation layer spin-coated on the top of the ordered porous material; 304 is a nanometer fluorescent material color conversion layer embedded in the ordered porous material channel growth; 305 is a channel side wall of the ordered porous material layer grown with the substrate; 306 is a single light source placed or grown at the bottom of the channel; 307 is a cathode contact point plated on the substrate in the ordered porous material channel; 308 is an anode contact point plated on the substrate in the ordered porous material channel; 309 is a substrate;

[0056] Figure 4 In the figure, 401 is a sapphire glass layer; 402 is a silicon dioxide packaging layer; 403 is an electron transport layer; 404 is a multi-quantum well layer; 405 is a hole transport layer; 406 is a transparent electrode layer; 407 is an anode contact electrode; 408 is a cathode contact electrode;

[0057] Figure 5 In the figure, 501 is a sapphire glass layer; 502 is a silica encapsulation layer; 503 is an electron transport layer; 504 is a multi-quantum well layer; 505 is a hole transport layer; 506 is a transparent electrode layer; 507 is an anode contact electrode; 508 is a cathode contact electrode;

[0058] Figure 6 In the figure, 601 is RGB light converted from the color conversion layer in the ordered porous material channel; 602 is a special functional layer grown on the isolation layer; 603 is an isolation layer spin-coated on the top of the ordered porous material; 604 is a nano-fluorescent material color conversion layer embedded in the ordered porous material channel; 605 is a high-reflectivity ordered porous material channel wall grown in a trumpet shape on the substrate; 606 is a single light source placed or grown at the bottom of the channel; 607 is a cathode contact point plated on the substrate in the ordered porous material channel; 608 is an anode contact point plated on the substrate in the ordered porous material channel; 609 is a substrate. DETAILED DESCRIPTION

[0059] To make the features and advantages of the present patent more apparent, the following specific examples are provided, and are described in detail as follows:

[0060] It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the application. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

[0061] It should be noted that the terms used herein are merely for the purpose of describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, the singular form is intended to include the plural form unless the context clearly indicates otherwise.

[0062] The embodiment of the present application provides a kind of ultra-high resolution display screen based on ordered porous material framework limit domain pixel, this display screen structure can improve the luminous efficiency of LED, OLED or QLED, and simultaneously effectively reduce the crosstalk between LED, OLED or QLED array pixel, so that display screen has low power, high efficiency light source and higher quality image.The display screen framework is the ordered porous material layer of which side wall is vertical or inclined to substrate growth, the structural characteristics of single pixel framework is symmetrical along the central axis, and the direction of pore or the direction of pore central axis of pixel framework is perpendicular to substrate.The display screen is electroluminescent type panel, first place or grow monomer multi-primary light source in the growth ordered porous material framework, make it as sub-pixel or display pixel, then use encapsulation solvent to prepare a layer of isolation layer on monomer light source in pore, finally bond with driving substrate to realize panel preparation.If it is photoluminescent type panel, it needs to prepare a layer of nanometer fluorescent material color conversion layer on monomer light source.If it is needed to process light, optical layer can be added on encapsulation layer.

[0063] Among them, ordered porous material framework is ordered porous material vertically or inclined growth on substrate, wherein ordered porous material can be selected as high reflectivity material, including but not limited to titanium dioxide, aluminum oxide, silver oxide, etc., can also be selected as high light absorption material, including but not limited to carbon black, etc., its pore inner diameter can be divided into ordered mesoporous material, ordered mesoporous material and ordered macroporous material, its overall inner diameter is in the range of 0.01nm-1 μm, and pore arrangement is dense and ordered, and pore shape is not limited to circular, can be square, triangular, rhombic, etc.When the pixel framework selects high reflectivity material, light that cannot be emitted from cross section at large angle in pore can be polymerized, and is emitted from cross section at top of pore through multiple total reflection, which can greatly improve quantum dot radiation recombination rate and improve light emission efficiency;When the pixel framework selects high absorption material, light that cannot be emitted from pore cross section can be absorbed, and acts as black matrix.Both can avoid crosstalk problem between adjacent pixels during display.In full-color display, pixel arrangement mode including but not limited to standard primary color RGB, Pentile, Delta, diamond arrangement, etc.can be formed.In monochrome display, side wall framework can act as isolation pixel.

[0064] One or more monomer light sources are placed or grown in each channel of the ordered porous material framework, the size of the monomer light source is equal to or smaller than the size of the channel, the inclined side wall channel can place a trapezoidal structure monomer light source matching the side wall channel, which helps to collect and collimate light. The contact electrode of the monomer light source is pre-plated on the substrate at the bottom of the ordered porous material, so as to be connected to the driving circuit later. The monomer light source includes but is not limited to LED (including Mini-LED, Micro-LED, Nano-LED, etc.), OLED (including Mini-OLED, Micro-OLED, etc.) and QLED, etc.

[0065] The isolation layer material includes but is not limited to a sealing material such as silicone, which is used to package the top of the ordered porous material, which can protect the structure of the ordered porous material and improve the stability of the structure. Other functional layers with special functions include but are not limited to a diffusion plate layer with light homogenization function, a metasurface layer with light collimation function, and a polarizer layer with polarization characteristics, etc.

[0066] The nano-fluorescent material color conversion layer is formed on the surface of the bottom light source by in-situ growth, inkjet printing or evaporation, etc., and can fill the channel and be excited to emit light by the bottom light source. The nano-fluorescent material includes but is not limited to quantum dot material, organic dye molecule and phosphor, etc.

[0067] The bottom light source can be a monomer light source confined in the channel of the ordered porous material, or a full-surface light source at the bottom of the substrate of the ordered porous material. If it is a monomer light source, the display panel can realize full-color display or controllable monochrome display, and if it is a surface light source, the framework acts as a pixel isolation function to realize monochrome display of the panel.

[0068] The display type of the ultra-high resolution display screen can be divided into electroluminescent type panel and photoluminescent type panel. If it is a photoluminescent type panel, the monomer light source acts as an excitation light source of the nano-fluorescent material color conversion layer, which can be a blue or ultraviolet light source, and each primary color light is generated by the excitation light source and the quantum dot color conversion layer excited by the excitation light source. For the electroluminescent type panel, the monomer multi-primary color light source acts as the display pixel or sub-pixel of the panel. The pixel color is determined by the monomer light source in the channel, and the corresponding primary color light source can be prepared in the channel according to the arrangement requirements of each primary color pixel, or the multi-primary color pixel can be expanded to realize a wider color gamut range.

[0069] The method for manufacturing the ordered porous material frame of the ultra-high resolution display screen. If the adjustment of the channel shape, channel inner diameter size, and channel side wall inclination is required, the processing of the grown basic structure can be realized by using methods such as ICP etching, laser beam etching, electron beam exposure, and ion beam exposure. For example, if an inverted trapezoidal channel structure is required, the initial ordered porous material vertically grown on the substrate is etched by etching technology to form a structure with a large upper part and a small lower part, or a small upper part and a large lower part. The center of the upper and lower outlet sections can be on a straight line and perpendicular to the substrate.

[0070] The method for manufacturing the single light source of the ultra-high resolution display screen. If the single light source is prepared first and then placed in the ordered porous material frame, the single light source peeled off from the outer substrate can be moved into the ordered porous material frame by fluid self-assembly, transfer printing, and other mass transfer technologies. If the single light source is directly grown in the ordered porous material frame, the single light source functional layer can be grown layer by layer by MOCVD and other technologies, and the ordered porous material frame plays a role of isolation.

[0071] The method for manufacturing the color conversion layer of the ultra-high resolution display screen. The color conversion layer material can include but is not limited to quantum dot material, organic dye molecule, and phosphor. If it is a quantum dot color conversion material, the quantum dot material can be grown in the hole by using methods such as ion exchange in-situ growth, room temperature supersaturation crystallization, ultrasonic synthesis, anhydrous toluene assisted method, and thermal injection method. Due to the confinement effect of the ordered porous material, the growth of the quantum dot particle size is controllable, and the obtained quantum dots fill the channel of the ordered porous material. The quantum dots with a pore size matching the ordered porous material can also be prepared in advance, and assembled into the corresponding ordered porous material channel by wet mixing, evaporation, or PDMS template transfer. The quantum dots include but are not limited to perovskite quantum dots, cadmium selenide quantum dots, and carbon quantum dots.

[0072] The method for manufacturing other functional layers of the ultra-high resolution display screen, which includes but is not limited to the preparation of a diffusion plate layer with approximately uniform scattering performance by coating, texture design, and processing steps, the preparation of a metasurface layer with light collimation function by electron beam evaporation, chemical plating, and magnetron sputtering processing methods, and the preparation of a polarizing plate layer with light filtering effect by chemical vapor deposition, physical vapor deposition, hot pressing method, and stretching method.

[0073] The full-color implementation method of the ultra-high resolution display screen. If it is a photoluminescence type panel, the pixel sizes of different colors can be the same or can be different by changing the inner diameter of the hole. When the inner diameter of the hole is the same, the inkjet printing technology can be used to fill the base color nanophosphor material into the hole of the ordered porous material. Due to the confinement effect of the ordered porous material frame, under the condition that the filling height is equal and the light emitting area size is equal, the concentration of each base color nanophosphor material is controlled to balance the light emitting intensity of the light emitting pixels of different colors, and the control of the overall color balance is realized. When the inner diameter of the hole needs to be adjusted, the hole needs to be etched (such as ICP etching technology), the shape of the hole is changed, the color conversion layer is confined by the hole, the particle size can be controlled to realize the control of different light emitting colors, or the halogen element can be changed to change the color of the color conversion layer. Or the prepared color conversion material can be filled into the hole by wet mixing. Because the particle sizes of nanophosphor materials of different colors are different, the matching inner diameters of the holes are also different, so the monochromatic wet filling method can be used according to the order of light emitting colors to realize the sequential filling of the holes from small to large. The color conversion layer manufacturing method includes but is not limited to the above method. If a full-color electroluminescence pixel scheme is prepared, the prepared multi-base color LED or QLED monomer can be positioned and attached, imprinted and transferred, solidified and processed and the like by the PDMS transfer method, and the monomer light source can be arranged in the hole by repeating the transfer to realize the full-color pixel arrangement of the monomer light source in the hole, or the ordered porous material isolation layer can be grown between the ITO anode and the transparent cathode electrode of the OLED. The steps include but are not limited to sputtering growth of the ITO electrode layer on the substrate, etching of the ITO and filling of the isolation column, growth of the ordered porous material frame, filling of the nanophosphor material, growth of the transparent cathode electrode layer, etching of the transparent electrode and filling of the cathode isolation layer, and packaging. The nanophosphor material can be placed in the hole of the ordered porous material by inkjet printing or evaporation technology, and the full-color pixel arrangement of the panel can be realized by changing the nanophosphor material in the hole. For the light emitting regulation of the monomer light source, the excitation current size of each color monomer light source can be regulated to realize the regulation of the overall light emitting intensity and the color balance, or the hole can be etched to form a hole structure with different inner diameters, the size of the display pixel can be changed to realize the regulation of the light emitting.

[0074] The following will be further described and introduced by two specific implementation cases:

[0075] Example 1

[0076] The display screen structure provided in the embodiment is as Figure 1As shown, it comprises: substrate 101, ordered porous material layer 102, isolation layer 103, other special functional layer 104. Specifically, the ordered porous material layer 102 is grown on the upper surface of the substrate 101, the isolation layer 103 is spin-coated on the top of the ordered porous material layer 102, and the other special functional layer 104 is grown on the top of the isolation layer 103.

[0077] The present application proposes to use ordered porous material as the pixel frame of the ultra-high resolution display screen, and each channel is a display pixel or sub-pixel, such as Figure 2 As shown in the top view of the RGB pixel distribution diagram of the ultra-high resolution display screen based on the ordered porous material frame limited pixel of the present application, 201 is the ordered porous material frame, 202 is the R sub-pixel light emitting point, 203 is the G sub-pixel light emitting point, and 204 is the B sub-pixel light emitting point.

[0078] Specifically, the ordered porous material layer 102 can be selected as a high reflectivity material, including but not limited to titanium dioxide, aluminum oxide, silver oxide, etc., and can also be selected as a high light absorption material, including but not limited to carbon black, etc., the inner diameter of the channel can be divided into ordered mesoporous material, ordered mesoporous material and ordered macroporous material, the overall inner diameter is in the range of 0.01 nm-1 μm, and the channels are densely arranged and ordered, and the channel shape is not limited to circular, but can be square, triangular, rhombic, etc. When the pixel frame selects a high reflectivity material, the light that cannot be emitted from the cross section at a large angle in the channel can be aggregated, and the light can be emitted from the top cross section of the channel through multiple total reflections, which can greatly improve the quantum dot radiation recombination rate and improve the light emitting efficiency; when the pixel frame selects a high absorption material, the light that cannot be emitted from the channel cross section can be absorbed, acting as a black matrix. Both can avoid the crosstalk problem between adjacent pixels during display. In full-color display, the pixel arrangement mode can include but is not limited to standard base color RGB, Pentile, Delta, diamond arrangement, etc. In monochrome display, the side wall frame can act as a pixel isolation function. The method for manufacturing the ordered porous material frame layer includes but is not limited to the following methods:

[0079] Method one

[0080] (1) Mix decane, CTAB, and ethanol in a container as a template agent solution.

[0081] (2) Take a beaker, add ethanol, add tetrabutyl titanate (TBOT) to it, and then add the "tetrabutyl titanate-anhydrous ethanol solution" drop by drop into a container bottle mixed with dilute hydrochloric acid "PH=4-5" and deionized water to hydrolyze it, stir for 2 hours, and take the layered milky white liquid as a titanium source solution.

[0082] (3) Add titanium source solution to ammonia solution, stir overnight at constant temperature (50 degrees Celsius), and repeatedly wash the glass slide with ordered porous material with nitrogen and deionized water to remove residual solvent.

[0083] (4) Place the glass slide in a muffle furnace and heat it to 300°C at 5°C / min for 1 hour, hold it for 2 hours, then heat it to 600°C at 5°C / min for 1 hour, hold it for 2 hours, remove the template agent and shape the titanium dioxide, and finally obtain a substrate with ordered porous material with vertical substrate growth.

[0084] Method 2

[0085] (1) Mix CTAB, ethanol and hydrochloric acid in a container and stir for 30 minutes to fully dissolve CTAB.

[0086] (2) Add tetrabutyl titanate (TBOT) dropwise to the solution in (1), then add a small amount of water and dry for 24 hours.

[0087] (3) Take the above gel, add it to ethanol, stir vigorously, then add ammonia solution and decane, and heat thoroughly at 50 degrees Celsius.

[0088] After mixing for 30 minutes, add the glass substrate to the template solution and stir for more than 6 hours.

[0089] (4) The glass slide obtained in step (4) is repeatedly washed with nitrogen and deionized water to remove residual solvent.

[0090] (5) Place the cleaned glass slide into a dilute hydrochloric acid-ethanol solution and extract the organic matter in the pores multiple times.

[0091] If it is necessary to prepare an ordered porous material layer with tilted sidewalls, the sidewalls of the ordered porous material substrate with vertical structure are etched into a tilted structure using ICP etching.

[0092] Specifically, such as Figure 3 The diagram shows a cross-sectional view of a photoluminescent display screen. 301 is RGB emitted light after color conversion within the pores of the ordered porous material; 302 is a special functional layer grown on the isolation layer; 303 is an isolation layer spin-coated onto the top of the ordered porous material; 304 is a nano-fluorescent material color conversion layer embedded within the pores of the ordered porous material; 305 is the sidewall of the pores in the ordered porous material layer grown on the substrate; 306 is a single light source placed or grown at the bottom of the pores; 307 is a cathode contact point deposited on the substrate within the pores of the ordered porous material; 308 is an anode contact point deposited on the substrate within the pores of the ordered porous material; and 309 is the substrate. The fabrication methods for the nano-fluorescent material color conversion layer within the pores include, but are not limited to, the following methods:

[0093] Method 1

[0094] (1) Add cesium carbonate, octadecene, and oleic acid to a 50 ml three-necked flask and purge with nitrogen gas for 15 minutes (to remove impurities).

[0095] (Except for other gases in the bottle), stir and heat to the solvent temperature of 120 degrees Celsius and maintain for 1 hour, then raise the temperature to 150 degrees Celsius until the cesium carbonate is completely dissolved, and then cool to room temperature for later use as a cesium oleate precursor.

[0096] (2) Add lead bromide, octadecene, and the ordered porous material substrate to a 50ml three-necked flask, and then heat at 80 degrees Celsius.

[0097] Nitrogen gas was introduced and stirred for 1 hour. Then, the temperature was raised to 120 degrees Celsius and oleic acid and oleylamine were added. After the lead bromide was completely dissolved, the temperature was raised to 150 degrees Celsius and the preheated cesium oleate precursor was quickly injected.

[0098] (3) After reacting for 10 seconds, the substrate of ordered porous material is cooled in an ice bath, and the quantum dots attached to the outside of the pores are removed.

[0099] Method 2

[0100] (1) Cesium bromide and lead bromide are dissolved in DMF to obtain perovskite precursors.

[0101] (2) Spin-coating the perovskite precursor solution onto an ordered porous material substrate.

[0102] (3) Toluene is dropped onto an ordered porous material substrate coated with perovskite precursor to induce perovskite supersaturation crystallization.

[0103] (4) Remove quantum dots attached to the outside of the hole.

[0104] Specifically, to achieve better sidewall reflection, the grown base structure can be processed using methods such as ICP etching, laser beam etching, electron beam exposure, and ion beam exposure, but not limited to these. For example, if an inverted trapezoidal channel structure is required, etching technology can be used to etch the initially ordered porous material grown vertically on the substrate, creating a structure that is either larger at the top and smaller at the bottom, or vice versa. The centers of the upper and lower exit sections can be aligned on a straight line and perpendicular to the substrate. A schematic diagram is shown below. Figure 6As shown, including 601 is the RGB light emitted from the color conversion in the pore channel of the ordered porous material; 602 is a special functional layer grown on the isolation layer; 603 is an isolation layer spin-coated on the top of the ordered porous material; 604 is a nanophosphor color conversion layer grown in the pore channel of the ordered porous material; 605 is a high-reflectivity ordered porous material pore channel wall grown in a horn shape inclined to the substrate; 606 is a single light source placed or grown at the bottom of the pore channel; 607 is a cathode contact point plated on the substrate in the pore channel of the ordered porous material; 608 is an anode contact point plated on the substrate in the pore channel of the ordered porous material; 609 is a substrate. Its structure is as shown in Figure 3 The difference is that 605 is a high-reflectivity ordered porous material pore channel wall grown in a horn shape inclined to the substrate.

[0105] Specifically, the bottom single light source of the photoluminescence type display screen matches the pore channel topography and can be placed inside the pore channel by growth or fluid assembly method, etc. If the bottom single light source is prepared by self-growth method, its vertical pore channel light source structure is as shown in Figure 5 As shown, the inclined side wall structure light source is as shown in Figure 4 As shown, the vertical pore channel single light source structure layer can be divided into sapphire glass layer 501 (401), silicon dioxide encapsulation layer 502 (402), electron transport layer 503 (403), multi-quantum well layer 504 (404), hole transport layer 505 (405), transparent electrode layer 506 (406), anode contact electrode 507 (407), and cathode contact electrode 508 (408).

[0106] Specifically, the growth method of the single light source includes but is not limited to the following methods:

[0107] Method one: preparation of LED single

[0108] (1) Use MOCVD process to grow epitaxial layers on sapphire substrate layer by layer.

[0109] (2) Use electron beam evaporation process to deposit silicon dioxide protective layer.

[0110] (3) Use ICP method to etch the hole.

[0111] (4) Make electrodes by evaporation technology.

[0112] Method two: use evaporation method to grow OLED single.

[0113] In addition, if the fluid self-assembly method is used to place the finished single light source matched with the pore channel, it can be as shown in Figure 7 As shown.

[0114] Specifically, the isolation layer material includes but is not limited to a sealing material such as silicone, which is used to encapsulate the top of the ordered porous material, both to protect the ordered porous material structure and to improve the stability of the structure. Other special functional layers include but are not limited to a diffusion plate layer with light homogenization function, a metasurface layer with light collimation function, and a polarizer layer with polarization characteristics, etc.

[0115] Specifically, the manufacturing method of other functional layers of the ultra-high resolution display screen includes but is not limited to preparing a diffusion plate layer with approximately uniform scattering performance through coating, texture design and processing steps, preparing a metasurface layer with light collimation function through electron beam evaporation, chemical plating, magnetron sputtering and other processing methods, and preparing a polarizer layer with light filtering function through chemical vapor deposition, physical vapor deposition, hot pressing method, stretching method and other processes.

[0116] Embodiment 2

[0117] As Figure 8 The preparation flow chart of a kind of electroluminescent OLED structure type display panel of the ultra-high resolution display screen based on ordered porous material framework confined pixel of the application is shown, the manufacturing method of ordered porous material framework layer and nano fluorescent material layer is same with embodiment 1. It includes sputtering growth ITO layer, ITO etching, growth ITO isolation column, sputtering growth transparent cathode layer, growth ordered void material framework layer, fill nano fluorescent material, sputtering growth transparent cathode layer, etching transparent cathode layer, growth cathode isolation layer, packaging and other steps.

[0118] It is worth noting that in full-color display, RGB pixels are divided into electroluminescent and photoluminescent types. Among them, the photoluminescent type pixel is a B pixel that excites quantum dots. The RGB pixels of the two types of light emitting can but not limited to adopt the standard arrangement mode, that is, each pixel on the screen is arranged by three closely adjacent RGB sub-pixels. After software simulation, the above-mentioned embodiment display screen has more uniform light spot than the traditional LED or OLED light emitting array, the pixel density per unit area is greatly improved, the color difference is obviously improved, and the cross talk between pixels is well avoided. The ultra-high resolution display screen of the present embodiment can facilitate the development of miniaturization, high imaging quality and high resolution display screen technology.

[0119] The present patent is not limited to the above best embodiment, and anyone can derive other various forms of an ultra-high resolution display screen based on ordered porous material framework confined pixel and its manufacturing method under the inspiration of the present patent. Any equivalent changes and modifications made within the scope of the patent application of the present invention shall be covered by the present patent.

Claims

1. An ultra-high resolution display screen based on confining pixels in an ordered porous material framework, characterized by: The ordered porous material grown on the substrate is used as a pixel frame of the display screen, and a light source is arranged at the bottom of the pore, so that the light source separated by the ordered porous material is a display pixel or sub-pixel of the super-high-resolution display screen; and an electroluminescent structure or a photoluminescent structure is formed on the basis; The substrate is provided with an isolation layer on the light source in the pore to encapsulate the top of the ordered porous material, and the contact electrode of the light source is pre-plated on the substrate at the bottom of the ordered porous material; The pixel frame is an ordered porous material layer grown with the side wall perpendicular or inclined to the substrate, a single pixel frame is symmetrical along the central axis, and the pore direction or pore central axis direction of the pixel frame is perpendicular to the substrate; the ordered porous material adopts a high-reflectivity or high-absorptivity material to avoid cross talk between pixels; The light source adopts a single monomer light source confined in the pore of the ordered porous material to realize full-color display or controllable monochrome display, and a single monomer multi-primary color light source matched with the aperture or smaller than the aperture is placed or grown at the bottom of each pore of the ordered porous material, so that each single monomer light source is a display pixel or sub-pixel of the super-high-resolution display screen; or a full-surface light source is arranged at the bottom of the substrate of the ordered porous material, and the frame acts as a pixel isolation at this time to realize panel monochrome display.

2. The ultra-high resolution display screen based on ordered porous material frame confined pixels according to claim 1, characterized in that: When the electroluminescent structure is adopted, the single monomer multi-primary color light source is used as the display pixel or sub-pixel of the panel, and when the photoluminescent structure is adopted, the light source acts as the excitation light source of the nanometer fluorescent material color conversion layer, and each primary color light is generated by the excitation light source and the nanometer fluorescent material color conversion layer excited thereby.

3. The ultra-high resolution display screen based on ordered porous material frame confined pixels according to claim 1, characterized in that: One or more of a diffusion plate layer, a metasurface layer, and a polarizer layer are arranged on the isolation layer.

4. The method of claim 1, wherein the method further comprises: providing a plurality of pixelated display screens; and providing a plurality of ordered porous material frames, each of the plurality of ordered porous material frames being configured to receive one of the plurality of pixelated display screens. When the electroluminescent structure is adopted, the preparation is carried out by the following steps: Step 1: providing a wafer or glass substrate with a clean surface, and growing an ordered porous material frame perpendicular to the substrate on the surface of the substrate by a template self-assembly method; Step 2: placing or growing a light source structure in each pore of the ordered porous material frame perpendicular to the substrate from bottom to top; Step 3: encapsulating by preparing an isolation layer; Step 4: bonding the panel with a driving substrate to form a display screen; When the photoluminescent structure is adopted, the preparation process of the nanometer fluorescent material color conversion layer is further included between Step 2 and Step 3; The color conversion layer material adopts quantum dot material, organic dye molecule or phosphor; if quantum dot color conversion material is adopted, one of ion exchange in-situ growth method, room temperature supersaturation crystallization method, ultrasonic synthesis method, anhydrous toluene auxiliary method and thermal injection method is used to grow in the pore, and based on the confinement of the ordered porous material, the quantum dot particle size growth is controllable, and the quantum dot fills the pore of the ordered porous material; or the quantum dots matched with the aperture of the ordered porous material are prepared in advance, and the quantum dots are assembled into the corresponding pore of the ordered porous material by wet mixing, evaporation or PDMS template transfer method; In Step 1, one of ICP etching, laser beam etching, electron beam exposure and ion beam exposure method is used to adjust the pore shape, pore inner diameter size and pore side wall inclination. In step 2, the light source adopts the placement or growth method of monomer light source. If the monomer light source is prepared first and then placed in the ordered porous material frame, the monomer light source peeled off from the outer substrate is moved into the ordered porous material frame by fluid self-assembly or mass transfer technology of transfer printing. If the monomer light source is grown directly in the ordered porous material frame, the functional layer of the monomer light source is grown layer by layer by MOCVD, and the ordered porous material frame plays a role of isolation.

5. The method according to claim 4, wherein the pixel size of different colors is the same or is adjusted differently by changing the inner diameter of the channel. When the inner diameter of the channel is the same, the inkjet printing technology is used to fill the nanometer fluorescent materials of different base colors into the channel of the ordered porous material. Due to the confinement effect of the ordered porous material frame, the light-emitting intensity of the light-emitting pixels of different colors is balanced by controlling the concentration of the nanometer color conversion materials of different base colors under the condition that the filling height and the light-emitting area size are the same. When the inner diameter of the channel needs to be adjusted, the channel is etched to change the shape of the channel, the color conversion layer is confined by the channel, and the light-emitting color is controlled by controlling the particle size or changing the halogen element. Or, the prepared color conversion materials are filled into the channel by wet mixing. Since the particle sizes of the nanometer fluorescent materials of different colors are different, the inner diameters of the matched channels are also different. Therefore, the wet filling method is used to fill the channels in sequence from large to small according to the order of the light-emitting colors. When the full-color electroluminescent panel is prepared, the prepared multi-base-color LED or QLED monomer is positioned and attached, imprinted and transferred, and cured by the PDMS transfer printing method, and the transfer printing is repeated to realize the full-color pixel arrangement of the monomer light source in the channel. Or, the ordered porous material isolation layer is grown between the ITO anode and the transparent cathode electrode of the OLED. The ITO electrode layer is sputtered and grown on the substrate, the ITO is etched and filled with isolation columns, the ordered porous material frame is grown, the nanometer fluorescent materials are filled, the transparent cathode electrode layer is grown, the transparent electrode is etched and filled with a cathode isolation layer, and the panel is packaged. The nanometer fluorescent materials are placed in the channel of the ordered porous material by inkjet printing or evaporation technology, and the full-color pixel arrangement of the panel is realized by changing the nanometer fluorescent materials in the channel. For the light-emitting regulation of the monomer light source, the excitation current of each color monomer light source is regulated to realize the regulation of the overall light-emitting intensity and color balance, or the channel is etched to form channel structures with different inner diameters to change the size of the display pixels and realize the regulation of the light-emitting.

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