Array Substrate Passivation Stack for Mini-LED Reflectivity
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Solution Overview
Problem
The use of white oil as a reflective layer in backlight modules composed of sub-millimeter light-emitting diodes (mini-LEDs) requires a separate coating process, increasing manufacturing costs.
Innovation Solution
An array substrate with a passivation layer comprising a stack of three dielectric layers with different refractive indices, which serves as a reflective layer, reducing manufacturing costs by eliminating the need for a separate coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If white oil is coated on backlight modules to create a reflective layer, then reflectivity is improved, but manufacturing cost increases due to separate coating process
Solution Approach 1:
The patent combines the reflective layer function with the passivation layer structure by integrating three dielectric layers with different refractive indices into the existing passivation layer. This merging eliminates the need for a separate white oil coating process while achieving comparable reflectivity (88% at 450nm wavelength), thereby reducing manufacturing steps and cost.
Solution Approach 2:
The patent uses a composite structure of three dielectric layers (first dielectric layer, second dielectric layer, and third dielectric layer) with different refractive indices to create the reflective function. This composite material approach replaces the traditional white oil coating with a multi-layer dielectric stack that achieves superior optical performance while being manufacturable through standard semiconductor processes.
2Illumination intensity
If white oil is used as reflective layer, then reflectivity is achieved, but manufacturing process complexity increases
Solution Approach 1:
The reflective layer functionality is merged into the passivation layer structure by incorporating three dielectric layers during the existing passivation process. This integration reduces manufacturing process complexity by eliminating separate coating steps while achieving 88% reflectivity at 450nm wavelength.
3Illumination intensity
If three dielectric layers with different refractive indices are stacked, then reflectivity increases to 88%, but layer structure complexity increases
Solution Approach 1:
The passivation layer structure is given multi-functionality by making it serve both as a protective passivation layer and as a reflective layer. The three dielectric layers with different refractive indices are designed to provide both passivation functionality and optical reflection (88% at 450nm), thereby reducing overall device complexity despite the multi-layer structure.
Solution Approach 2:
The patent optimizes specific parameters including the refractive indices of the three dielectric layers, their thicknesses, and material compositions to achieve the target reflectivity of 88% at 450nm wavelength. By carefully controlling these parameters, the patent achieves high reflectivity while managing the complexity of the multi-layer structure through standardized dielectric materials and process-compatible dimensions.
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
The passivation layer achieves high reflectivity, comparable to white ink, with a reflectivity of 88% for light with a wavelength of 450 nanometers, while reducing manufacturing costs and improving yield.
Implementation Method 1
the passivation layer comprises a first dielectric layer, a second dielectric layer and a third dielectric layer stacked in sequence... a refractive index of the first dielectric layer is different from a refractive index of the second dielectric layer, and the refractive index of the second dielectric layer is different from a refractive index of the third dielectric layer
Implementation Method 2
the refractive index of the second dielectric layer is greater than the refractive index of the first dielectric layer and the refractive index of the third dielectric layer... a difference between the refractive index of the second dielectric layer and the refractive index of the first dielectric layer is greater than or equal to 1 and is less than or equal to 3
Data Source
AI summary
An array substrate and a display panel are provided, the array substrate is disposed on the base substrate, and a passivation layer is formed on a side of the array substrate layer away from the base substrate. The passivation layer includes a first dielectric layer, a second dielectric layer, and a third dielectric layer stacked in sequence, the first dielectric layer is disposed close to the array layer and the third dielectric layer is disposed away from the array layer, a refractive index of the first dielectric layer is different from a refractive index of the second dielectric layer, and the refractive index of the second dielectric layer is different from a refractive index of the third dielectric layer.