Display Convex Refractive Layer for Dam-Free Planarization
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Solution Overview
Problem
Existing display devices face challenges in achieving high resolution and durability while maintaining reduced processing complexity, particularly in the manufacturing of micro-lens arrays for display panels.
Innovation Solution
A display device design featuring a refractive layer with a convex pattern and a protective layer aligned with the display area's boundary, eliminating the need for a dam in the planarization process, and using a combination of compounds like polysilsesquioxane-based and epoxy-based materials for improved durability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dam structure is used in the planarization process, then manufacturing precision can be improved, but device complexity and processing difficulty increase
Solution Approach 1:
The patent removes the dam structure from the planarization process entirely. The protective layer is formed directly on the refractive layer without requiring a dam, thereby eliminating the complexity associated with dam formation, alignment, and removal while maintaining adequate planarization precision for the display device manufacturing.
2Device complexity
If the protective layer is made thinner, then device complexity is reduced, but durability and reliability deteriorate
Solution Approach 1:
The patent specifies a protective layer thickness range of 20-500 micrometers, optimizing this parameter to achieve both reduced device complexity and improved durability. This thickness range provides sufficient mechanical protection and reliability while avoiding excessive layer complexity that would arise from multiple thinner layers or complex protective structures.
3Measurement precision
If high-resolution light emitting elements are used, then measurement precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The protective layer serves multiple functions simultaneously: it provides mechanical protection, enables precise alignment for high-resolution display elements, and maintains manufacturing feasibility. The layer's uniform thickness and extensive coverage area facilitate precise positioning of light emitting elements without requiring excessively tight manufacturing tolerances.
4Use of energy by moving object
If the refractive layer is made with higher refractive index, then light efficiency is improved, but material complexity increases
Solution Approach 1:
The refractive layer is constructed from composite materials comprising a polymer matrix (such as acrylic resin) combined with high-refractive-index particles or additives. This composite approach achieves the desired high refractive index (≥1.6) for improved light efficiency while maintaining material processing feasibility and avoiding excessive complexity that would result from using exotic single-material options.
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 design enhances the durability and reliability of display devices with high resolution, reducing manufacturing complexity and increasing productivity by eliminating the need for a dam in the planarization process.
Implementation Method 1
a refractive layer on the color filter... The refractive layer includes a cover layer that covers the color filter and a convex pattern between the cover layer and the protective layer
Implementation Method 2
The protective layer includes a first compound including at least one selected from among a polysilsesquioxane-based compound, a polyurethane-based compound, a polycarbonate-based compound, and a polyethylene terephthalate-based compound, a second compound including a surfactant including at least one selected from among a fluorine-containing compound and a silicon-containing compound, and a third compound including an epoxy-based compound
Data Source
AI summary
A display device includes a display area and a peripheral area adjacent to the display area. The display device includes a base layer, a display element layer on the base layer and including a light emitting element that overlaps the display area when viewed in a plane, a color filter on the display element layer, a refractive layer on the color filter, and a protective layer on the refractive layer. The refractive layer includes a cover layer that covers the color filter and a convex pattern between the cover layer and the protective layer and provided integrally with the cover layer. One end of the protective layer is aligned with a boundary between the display area and the peripheral area when viewed in the plane.