Column Spacer Design for Display Brightness Uniformity
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Solution Overview
Problem
Existing display apparatuses face challenges in maintaining uniform brightness and color accuracy due to variations in the spacing between light-emitting elements and color-converting materials, leading to inconsistent image display across different positions.
Innovation Solution
A display apparatus design featuring a light-emitting panel and a color panel with a filling layer in between, where column spacers maintain a uniform interval between light-emitting elements and color-converting materials, ensuring consistent brightness and color reproduction across the display area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If no column spacer is used, then the device structure is simpler, but the spacing between light-emitting elements and color-converting materials becomes non-uniform, causing brightness and color variations
Solution Approach 1:
A column spacer is introduced as an intermediary component between the light-emitting elements and the color-converting materials. This spacer maintains a uniform distance (15 μm or more) between corresponding elements, ensuring consistent optical performance across the display while adding minimal structural complexity.
Solution Approach 2:
The column spacer is positioned in advance during the manufacturing process to pre-establish the correct spacing relationship between light-emitting elements and color-converting materials. This preliminary positioning prevents spacing variations before they can affect display uniformity.
2Illumination intensity
If the distance between light-emitting elements and color-converting materials varies, then the device can be manufactured more easily without precise spacing control, but brightness and color accuracy become non-uniform across the display
Solution Approach 1:
The column spacer serves as a mechanical intermediary that physically enforces a minimum distance (15 μm or more) between light-emitting elements and color-converting materials. This spacer translates the abstract requirement for uniform brightness into a concrete dimensional constraint that can be easily controlled during manufacturing.
Solution Approach 2:
By specifying a minimum distance parameter (15 μm or more) between light-emitting elements and color-converting materials, the design changes the spacing parameter from a variable that causes non-uniformity to a controlled parameter that ensures uniformity. This parameter change is easily implementable in the manufacturing process.
3Reliability
If column spacers are added to maintain uniform spacing, then brightness and color accuracy improve, but the manufacturing process becomes more complex
Solution Approach 1:
The column spacer is a simple intermediary component that can be integrated into the existing manufacturing process. By positioning this spacer during assembly, the patent achieves reliable color accuracy without requiring complex manufacturing equipment or processes, thus minimizing the impact on manufacturing ease.
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 ensures uniform brightness and color accuracy by maintaining consistent spacing between light-emitting elements and color-converting materials, preventing variations in brightness and color reproduction across the display area.
Implementation Method 1
a functional layer in the central opening and including at least one of a color-converting material or a scatterer
Implementation Method 2
a functional layer in the central opening and including at least one of a color-converting material or a scatterer
Data Source
AI summary
A display apparatus includes: a lower substrate; a light-emitting element on the lower substrate and including an emission layer; an upper substrate over the lower substrate with the light-emitting element therebetween; a bank on a lower surface of the upper substrate facing the lower substrate, the bank including a central opening and a peripheral opening; a functional layer in the central opening and including at least one of a color-converting material or a scatterer; and a column spacer on the bank and facing the lower substrate. A distance from an outer surface of the column spacer to an inner surface of the bank is 15 μm or more in a plan view. The inner surface of the bank defines the peripheral opening.