Color-Converted Display Pixel Layout With Fewer Alignment Steps
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Solution Overview
Problem
The existing display device manufacturing process is costly and has low yield due to the repeated processes required for aligning light-emitting elements and forming color conversion layers, especially when using different color light-emitting elements and color conversion particles, which increases the complexity and inefficiency.
Innovation Solution
A display device design that incorporates a light-emitting layer with two kinds of light-emitting elements and color conversion layers containing the same kind of color conversion particles, where the color filter layers are used to transmit and block specific wavelengths of light, reducing the number of processes needed for alignment and fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different color light-emitting elements are used for each pixel, then color display capability is improved, but the number of alignment processes increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the light-emitting function into a single layer containing multiple color light-emitting elements (red, green, blue) while using a separate color conversion layer to generate the required colors. This combining approach reduces the number of alignment processes by eliminating the need to separately align different color light-emitting elements in different layers, thereby reducing manufacturing complexity while maintaining full color display capability.
2Ease of manufacture
If color conversion layers are formed above light-emitting elements to enable color conversion, then manufacturing process is simplified, but the number of formation processes increases and cost increases
Solution Approach 1:
The patent employs a universal color conversion layer that can convert blue light into multiple colors (green, red, yellow) depending on the color conversion particles used. This multi-functional layer eliminates the need for separate color conversion layers for each color, reducing the total number of formation processes and improving fabrication yield while maintaining ease of manufacture.
3Manufacturing precision
If multiple alignment processes are performed for light-emitting elements and color conversion layers, then alignment precision is improved, but manufacturing cost increases and yield decreases
Solution Approach 1:
The patent performs preliminary alignment by positioning both the light-emitting elements and color conversion particles in a single alignment process rather than multiple sequential processes. This preliminary action ensures sufficient alignment precision is achieved in one step, thereby improving fabrication yield by reducing the cumulative errors and losses associated with multiple alignment processes.
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 reduces the number of processes required for fabricating the display device, lowers production costs, and improves yield by simplifying the alignment and conversion of light colors, while also enhancing the luminous efficiency of specific light colors like green.
Implementation Method 1
color conversion particles that convert blue light into green light
Implementation Method 2
color filter layers... transmit and block specific wavelengths of light
Data Source
AI summary
A display device comprises first and second pixels, a light-emitting layer, color conversion layers, and color filter layers, the light-emitting layer comprising first and second light-emitting elements in the first and second pixels, wherein the color conversion layers comprise first and second color conversion layers in the first and second pixels, the color filter layers comprise first and second color filter layers in the first and second pixels, the first and second light-emitting elements emit first light having a central wavelength range of a first wavelength, the first and second color conversion layers contain color conversion particles converting the first light into second light having a central wavelength range of a second wavelength longer than the first wavelength, the first color filter layer transmits the first light and blocks the second light, and the second color filter layer transmits the second light and blocks transmission of the first light.