Color Conversion Panel Spacer and Reflective Layer Design
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Solution Overview
Problem
Existing color conversion panels in display devices face issues with variable gap inconsistencies between the display panel and the color conversion panel, leading to display quality deterioration and increased manufacturing costs due to the need for multiple exposure masks in the photolithography process.
Innovation Solution
A color conversion panel design featuring partitioning walls with reflective layers and overcoats having water repellency, spacers, and color conversion layers, including quantum dots, which maintains a constant gap and reduces the number of exposure masks required, thereby enhancing manufacturing efficiency and light conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple exposure masks are used in the photolithography process to manufacture the color conversion panel, then the manufacturing precision and quality of the color conversion layers are improved, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple exposure masks into a single integrated exposure mask that can perform multiple patterning operations. This merging approach maintains the manufacturing precision of multiple masks while reducing the overall manufacturing cost by eliminating the need to purchase, store, and operate multiple separate masks.
Solution Approach 2:
The exposure mask is designed with multi-functionality to perform multiple patterning tasks in a single device. The mask includes multiple patterning regions with different opening patterns that can sequentially form different color conversion layers (red, green, blue) without requiring mask changes, thus achieving universal applicability for multiple manufacturing steps.
2Device complexity
If the gap between the display panel and the color conversion panel is not constant, then the device complexity is reduced, but the display quality deteriorates and brightness varies by location
Solution Approach 1:
The patent incorporates a spacer structure in advance during the manufacturing process that pre-establishes a constant gap between the display panel and the color conversion panel. This preliminary action ensures uniform brightness and display quality across the entire panel without requiring complex post-manufacturing adjustments or quality control procedures.
Solution Approach 2:
The spacer acts as an intermediary element between the display panel and the color conversion panel, maintaining a precise and constant distance. This mediator structure simplifies the overall device design by providing a mechanical solution for gap control rather than requiring complex alignment systems or active control mechanisms.
3Use of energy by moving object
If quantum dots and reflective layers are added to improve light conversion efficiency, then the light efficiency increases, but the device complexity and manufacturing process become more complex
Solution Approach 1:
The patent combines the quantum dot color conversion layers with the reflective layer structure in an integrated design. The reflective layers are positioned to work synergistically with the quantum dots, reflecting unabsorbed light back through the color conversion layers to improve efficiency. This merging of functions reduces the need for separate components and simplifies the overall device architecture.
Solution Approach 2:
The patent converts the harmful loss of light that would otherwise be wasted into a beneficial resource by using reflective layers to redirect unabsorbed light back through the quantum dot layers. This approach transforms light loss into additional color conversion opportunities, improving overall efficiency without requiring additional active components.
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 solution maintains a consistent gap between the display and color conversion panels, improving display quality and reducing manufacturing costs by simplifying the manufacturing process while increasing light efficiency through the use of quantum dots and reflective layers.
Implementation Method 1
The color conversion layers may include quantum dots
Implementation Method 2
reflective layers disposed on outer surfaces of the partitioning walls
Implementation Method 3
overcoats disposed on outer surfaces of the reflective layers and having water repellency
Data Source
AI summary
A color conversation panel according to an embodiment may include partitioning walls disposed on a substrate, reflective layers disposed on outer surfaces of the partitioning walls, overcoats disposed outside on outer surfaces of the reflective layers and having water repellency, a spacer overlapping a part of the partitioning walls and protruding from a part of the overcoats, the spacer and the overcoats being formed on a same layer, and color conversion layers disposed on the overcoats and disposed in areas defined by the partitioning walls.