Color Conversion Filter Manufacturing via Photochemical Decomposition
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Solution Overview
Problem
Current methods for manufacturing color conversion filters face challenges in achieving high-resolution patterning and simplifying the manufacturing process, as higher density of color conversion material leads to efficiency issues like density extinction and decomposition, and traditional photolithography requires complex processes.
Innovation Solution
A method involving the formation of a color filter layer on a transparent substrate with a layer containing color conversion material and an optical radical generating agent, exposed to specific wavelengths of light to decompose the material, allowing for high-resolution patterning without the need for photolithography, using auxiliary ultraviolet light and heat to vaporize the agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the density of color conversion coloring material is increased to improve color conversion efficiency, then color conversion efficiency is improved, but density extinction and decomposition of the coloring matter occur
Solution Approach 1:
A polymerizable monomer is introduced as an intermediary substance to disperse the color conversion coloring matter particles. This monomer forms a matrix that holds the coloring matter particles, preventing their aggregation and decomposition while maintaining high color conversion efficiency. The polymerizable monomer acts as a protective medium that stabilizes the coloring matter during the manufacturing process.
2Reliability
If the thickness of the color conversion layer is increased to prevent density extinction and decomposition, then stability of coloring matter is improved, but manufacturing complexity increases due to photolithography requirements
Solution Approach 1:
The patent replaces the mechanical photolithography system with a photochemical decomposition system. Instead of using masks, alignment systems, and multiple coating steps, the invention uses light-induced decomposition of the polymerizable monomer to directly form the color conversion layer pattern. This substitution dramatically simplifies the manufacturing process while maintaining the ability to produce thin, stable color conversion layers.
3Manufacturing precision
If photolithography is used for patterning to achieve high resolution, then manufacturing precision is improved, but device complexity and number of manufacturing steps increase
Solution Approach 1:
The patent extracts and eliminates the photolithography steps from the manufacturing process. Instead of performing coating, exposure, mask registration, and development steps, the invention directly forms patterns through light-induced decomposition of the polymerizable monomer in the color conversion layer. This extraction of unnecessary steps reduces manufacturing complexity while maintaining high patterning resolution through the inherent properties of the photochemical process.
4Manufacturing precision
If the width of patterns is made smaller than film thickness for high resolution, then manufacturing precision is improved, but pattern shape reproducibility and pattern deformation occur
Solution Approach 1:
The patent applies preliminary action by first forming the color conversion layer with the polymerizable monomer dispersed throughout, then using light to trigger decomposition only in the desired pattern areas. This preliminary formation of the uniform layer followed by selective decomposition ensures that even when pattern widths are smaller than film thickness, the patterns maintain their shape fidelity without deformation, as the decomposition process occurs uniformly from the top surface.
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 method enables the formation of high-resolution color conversion layers with simplified manufacturing, reducing deformation and alignment issues, and allows for thicker layers without film thickness limitations, facilitating the production of micro-display devices.
Implementation Method 1
The layer of coloring matter is exposed to coloring matter decomposition light that is applied through the transparent substrate and the color filter layer, and is also exposed to auxiliary ultraviolet light that is applied from the side of the coloring matter layer. Thereby, a color conversion layer is formed at a position corresponding to the color filter layer.
Implementation Method 2
The optical radical generating agent is then vaporized by heat.
Implementation Method 3
color conversion coloring matter (or material) that absorbs near ultraviolet light, blue light, bluish green light, or white light and emits light in visible ranges through wavelength profile conversion
Data Source
AI summary
A method and apparatus for manufacturing a color conversion filter. The method includes forming a color filter layer on a transparent substrate. A coloring matter layer containing color conversion coloring matter and an optical radical generating agent are formed on the substrate and the filter layer. The coloring matter layer is exposed to coloring matter decomposition light applied through the substrate and the filter layer. The coloring matter layer also is exposed to auxiliary ultraviolet light applied from the side of the coloring matter layer. This forms a color conversion layer at a position corresponding to the filter layer. The optical radical generating agent is heat vaporized. The color conversion coloring matter is decomposed by light whose wavelength is outside a range that the color filter layer transmits. The coloring matter decomposition light includes a wavelength component that decomposes the color conversion coloring matter. The color conversion layer emits, through wavelength profile conversion, light that the color filter layer transmits.