Color Conversion Substrate Edge-Thick Layer Against Material Intrusion
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Solution Overview
Problem
Existing display devices with color conversion substrates face reliability issues due to external material intrusion through the low refractive layer, leading to defects.
Innovation Solution
A color conversion substrate design with a low refractive layer that increases in thickness from the outer to inner areas, combined with a protective layer covering the side surfaces, prevents material intrusion by minimizing exposed surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the low refractive layer is made thin to maintain structural simplicity, then manufacturing is easier and device complexity is reduced, but external materials can intrude through the layer causing defects
Solution Approach 1:
The low refractive layer is designed with non-uniform thickness, being thicker at the edges and thinner at the center. This local variation in thickness provides enhanced protection at the edges where material intrusion is most likely to occur, while maintaining overall structural simplicity and avoiding the need for completely complex multi-layer structures.
Solution Approach 2:
The patent addresses the protection problem by transitioning from a uniform two-dimensional layer to a three-dimensional structure with varying thickness. The edge-thicker design adds a dimensional aspect to the layer structure, providing enhanced protection at critical areas without requiring additional layers throughout the entire structure.
2Reliability
If the low refractive layer thickness is increased uniformly across the substrate, then protection against material intrusion is improved, but manufacturing precision requirements increase and production becomes more difficult
Solution Approach 1:
Instead of requiring uniform high thickness across the entire substrate, the patent applies thickness variation locally - thicker at edges where protection is most needed and thinner at the center. This local quality approach reduces overall manufacturing precision requirements compared to uniform thick layers, as the critical protection is concentrated where most needed.
Solution Approach 2:
The patent applies excessive thickness only where necessary (at the edges) rather than uniformly across the entire substrate. This partial application of excessive thickness provides adequate protection at critical areas while avoiding the manufacturing precision challenges associated with uniformly thick layers across the whole substrate.
3Productivity
If the low refractive layer has uniform thickness, then manufacturing process is simpler and production efficiency is higher, but edge protection is insufficient allowing material intrusion
Solution Approach 1:
The patent implements local quality by making the low refractive layer thicker at the edges and thinner at the center. This can be achieved through manufacturing techniques such as spin coating or dip coating where the edge effect naturally creates the desired thickness variation, thus maintaining manufacturing efficiency while improving edge protection effectiveness.
Solution Approach 2:
The patent transitions from a uniform two-dimensional layer to a three-dimensional structure with thickness variation. This dimensional change can be achieved through standard manufacturing processes that naturally create edge-thicker profiles, maintaining productivity while enhancing edge protection without requiring complex additional manufacturing steps.
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 design enhances the reliability of the display device by reducing defects and improving durability through effective prevention of external material ingress.
Implementation Method 1
a low refractive layer on the color filter layer, under the sealing member, and increasing in thickness from the third area to the second area in at least a portion of the third area
Data Source
AI summary
A color conversion substrate, a display device including the color conversion substrate, and a method of manufacturing the color conversion substrate are provided. The color conversion substrate includes: a first base substrate including a first area, a second area around the first area, and a third area around the second area; a sealing member on the first base substrate and in the second area; a color filter layer on the first base substrate and under the sealing member; and a low refractive layer on the color filter layer, under the sealing member, and increasing in thickness from the third area to the second area in at least a portion of the third area.