Cover Unit Layer Stack for Display Color Yield
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Solution Overview
Problem
Current cover unit manufacturing processes face challenges in achieving high yield and consistency in implementing various colors and visual effects for display devices, leading to variations in product quality and increased production complexity.
Innovation Solution
The cover unit design incorporates a reflective layer, color layer, and pattern layer, where the color layer is optimized to control light transmittance and reflectance, allowing for simplified processes to achieve specific colors and visual effects, with the reflective layer serving as a common layer to maintain consistency across different color implementations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex processes are used to implement various colors and visual effects, then color implementation capability is improved, but manufacturing yield deteriorates
Solution Approach 1:
The cover unit is divided into multiple functional layers: a base layer, a color layer with first pattern, and a reflective layer with second pattern. This segmentation allows each layer to be optimized independently for its specific function while maintaining overall manufacturing simplicity and high yield.
Solution Approach 2:
Different regions of the cover unit have different optical properties through the patterned layers. The color layer provides color in specific areas while the reflective layer enhances reflectance in other areas, allowing localized optimization of visual effects without complicating the overall manufacturing process.
2Adaptability or versatility
If multiple processes are used to achieve various colors, then color variety is improved, but production complexity deteriorates
Solution Approach 1:
The reflective layer serves multiple functions: it provides reflectance enhancement, acts as a structural element, and can be patterned to create different visual effects. This multi-functionality reduces the need for separate processes for each function, simplifying production while maintaining color variety.
Solution Approach 2:
The cover unit combines different material layers with distinct optical properties (color layer with pigments/dyes and reflective layer with metallic or dielectric materials) to achieve various colors and visual effects through material composition rather than complex processing sequences.
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 design enhances manufacturing yield by reducing color variations and simplifying the process of implementing various colors, resulting in improved product quality and reduced production complexity.
Implementation Method 1
a reflective layer disposed between the display panel and the pattern layer... The reflective layer may impart a metallic effect
Implementation Method 2
an adhesive layer disposed between the color layer and the first base member
Data Source
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AI summary
A display device includes a cover unit and a display panel coupled to the cover unit. The cover unit includes a first base member disposed on the display panel and including a first area and a second area when viewed in a plan view, a pattern layer disposed between the first base member and the display panel, a color layer disposed between the first base member and the pattern layer and having a light transmittance, and a reflective layer disposed between the display panel and the pattern layer.