Color Array Panel Manufacturing Using Light Regeneration Layers
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Solution Overview
Problem
Current display systems face inefficiencies due to significant light wastage and conversion into harmful heat, leading to high costs and reduced performance and lifetime.
Innovation Solution
The implementation of light regeneration materials and notch filters or pass band filters to enhance optical efficiency, reduce color shift, and improve wide color gamut display operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If color filters are used to produce specific colors from broadband light, then color gamut is improved, but light efficiency deteriorates due to blocking of unwanted wavelengths
Solution Approach 1:
The patent changes the fundamental parameter of light generation from passive filtering to active wavelength conversion. By using quantum dots with specific size parameters, the system converts blue light to red and green wavelengths through photoluminescence, achieving wide color gamut while maintaining high light efficiency since conversion rather than blocking is used.
Solution Approach 2:
The patent substitutes the mechanical/optical filtering mechanism with a photoluminescent conversion mechanism. Instead of using color filters that physically block wavelengths, the invention uses quantum dots that actively convert blue light into red and green wavelengths through photonic processes, thereby eliminating the energy loss associated with blocking.
2Stability of the object's composition
If multiple optical components are used to achieve wide color gamut and high luminance, then display performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple functions into a single component layer. The quantum dot layer simultaneously performs color conversion, wavelength transformation, and color gamut expansion that would traditionally require multiple separate optical components, thereby simplifying the manufacturing process and reducing costs.
Solution Approach 2:
The quantum dot layer serves multiple functions: it converts blue light to red wavelengths, converts blue light to green wavelengths, and maintains high luminance output. This multi-functionality in a single layer reduces the number of components needed and simplifies manufacturing.
3Illumination intensity
If broadband light is used to illuminate pixel elements, then luminance is improved, but heat generation increases due to light wastage
Solution Approach 1:
The patent converts the harmful effect of light wastage into a beneficial process. Instead of allowing blocked light to become waste heat, the quantum dots absorb the 'wasted' blue light wavelengths and convert them into useful red and green light, transforming potential heat generation into productive wavelength conversion that maintains luminance while reducing heat.
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 increases the amount of usable light, reduces intermediate colors that desaturate primary colors, and enhances the overall efficiency and performance of display systems.
Implementation Method 1
a first light regeneration layer (106-1) configured to convert blue light to red light and pass green light; a second light regeneration layer (106-2) configured to convert blue light to green light and pass red light
Implementation Method 2
a first filter layer (302-1) configured with a first opaque or low transmittance range (notch) between blue and green light spectral power distributions and between green and red light spectral power distributions; a second filter layer (302-2) configured with a second opaque or low transmittance range (notch) between blue and green light spectral power distributions and between green and red light spectral power distributions
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3C
AI summary
A method, comprising individually reducing each stack sheet of two or more stack sheets to a respective thickness, wherein at least one of the two or more stack sheets comprises light regeneration materials, and wherein each stack sheet corresponds to each subpixel type of a display panel; stacking the sheets in an order that matches an order in which a plurality of subpixel types is stacked in the display panel; repeatedly cutting, across each stacked sheets along a first planar direction of the sheets, the stacked sheets into stacking segments, wherein each of the stacking segments is of a same specific thickness; rotating the stacking segments around the first planar direction by 90 degrees; and stacking the stacking segments along a second planar direction of sheets orthogonal to the first planar direction, to form a light regeneration layer that comprises a specific pitch of the sheets along the second planar direction, wherein the specific pitch matches a pitch of the plurality of subpixels.