Curved Encapsulation for Light Source Adhesion
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Solution Overview
Problem
In reflective display screens, the front light source and display panel often fail to adhere fully due to uneven surfaces, leading to display defects and air bubbles, especially when ambient light is insufficient.
Innovation Solution
A light source assembly with a substrate, a first light-blocking pattern, a first light-emitting unit, and an encapsulation portion with a curved outer surface, which prevents light leakage and ensures proper adhesion with the display panel, comprising a micro LED with three color sub-units and transparent conductive wiring, and a refractive index matching the adhesive layer for improved display efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the front light source and display panel are adhered using conventional flat structures, then the manufacturing process is simple, but the adhesion is incomplete resulting in air bubbles and display defects
Solution Approach 1:
The patent applies curvature by designing the encapsulation structure with a curved outer surface instead of a flat surface. This curved surface enables complete contact with the display panel during adhesion, eliminating air bubbles and ensuring full optical coupling between the light source and display panel, thereby resolving the adhesion quality issue.
2Manufacturing precision
If the outer surface of the encapsulation portion is made flat, then the manufacturing process is simpler, but light leakage occurs and display uniformity is poor
Solution Approach 1:
The curved outer surface of the encapsulation portion serves dual functions: it prevents light leakage by providing better optical confinement and ensures uniform contact with the display panel for consistent light distribution. This curvature design achieves both display uniformity and manageable manufacturing through standard encapsulation processes.
Solution Approach 2:
The patent modifies the geometric parameter of the encapsulation surface from flat to curved. This parameter change optimizes both optical performance (preventing light leakage) and display uniformity while maintaining compatibility with existing manufacturing capabilities through adjusted encapsulation material deposition processes.
3Reliability
If the light-emitting unit is directly exposed without encapsulation, then the structure is simpler, but light leakage occurs and display quality deteriorates
Solution Approach 1:
The encapsulation portion envelops the light-emitting unit and light-blocking pattern within its structure, creating a nested configuration. This nesting provides optical confinement to prevent light leakage while integrating multiple functions (protection, light management, and adhesion interface) into a single unified structure, balancing display quality with structural efficiency.
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 enhances display quality by preventing air bubbles and light leakage, ensuring uniform illumination and improved display effects in both sufficient and insufficient ambient light conditions.
Implementation Method 1
an outer surface of the encapsulation portion is a curved surface
Implementation Method 2
a first light-blocking pattern disposed on the substrate; a first light-emitting unit disposed on the first light-blocking pattern
Data Source
AI summary
A light source assembly, includes: a substrate; a first light-blocking pattern disposed on the substrate; a first light-emitting unit disposed on the first light-blocking pattern; and an encapsulation portion disposed on the substrate and enveloping the first light-blocking pattern and the first light-emitting unit; wherein an outer surface of the encapsulation portion is a curved surface. A display module and a method of manufacturing the light source module are further provided.