Display Panel Buffer Layer Geometry for Light Leakage Reduction
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Solution Overview
Problem
The existing display panel technologies face issues with light leakage and image quality due to the rough cutting surfaces of the buffer layer during the manufacturing process, leading to inefficient light emission and reflection towards the optical conversion layer.
Innovation Solution
The display panel design includes a buffer layer with a side surface that forms a first acute angle and a first obtuse angle, allowing light to be directed towards the driving backplane, reducing light leakage by increasing the probability of light being emitted towards the driving backplane and minimizing reflection towards the optical conversion layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the buffer layer is cut during manufacturing, then the optical device layer can be separated into individual devices, but the cutting surface becomes rough causing light leakage and reduced image quality
Solution Approach 1:
The buffer layer side surface is designed with an asymmetric inclined structure rather than a vertical cut. The side surface forms a first acute angle with the first surface and a first obtuse angle with the second surface, creating an asymmetric profile that directs light away from the optical conversion layer and reduces light leakage while maintaining ease of manufacturing
Solution Approach 2:
The cutting process is modified to create specific angle parameters. The side surface is formed at controlled angles (first acute angle with the first surface, first obtuse angle with the second surface) to optimize light direction. This parameter change transforms the rough cutting surface into a functional inclined surface that solves the light leakage problem
2Reliability
If light is emitted towards the optical conversion layer, then the optical conversion function can be achieved, but light leakage occurs reducing display performance
Solution Approach 1:
The asymmetric inclined side surface of the buffer layer directs light preferentially towards the driving backplane rather than the optical conversion layer. By forming the side surface at specific asymmetric angles (acute angle with first surface, obtuse angle with second surface), the structure guides light away from the optical conversion layer, reducing light leakage while preserving necessary optical conversion for display function
Solution Approach 2:
The cutting process that initially creates a harmful rough surface is transformed into a beneficial inclined surface. The same cutting operation that separates devices is used to create the asymmetric angle structure, converting what was a manufacturing defect (rough cut) into a functional feature that directs light away from the optical conversion layer and reduces light leakage
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 the image quality by reducing light leakage and improving the brightness uniformity across sub-pixel regions, resulting in better display performance.
Implementation Method 1
The adhesive layer is located between the buffer layer of each of the plurality of optical devices of the optical device layer and the optical conversion layer. The adhesive layer is in contact with the first surface of the buffer layer of each of the plurality of optical devices.
Implementation Method 2
A refractive index of the adhesive layer is less than a refractive index of the buffer layer of each of the plurality of optical devices.
Implementation Method 3
the side surface intersects with a first surface of the buffer layer of the optical device to form a first acute angle, and the side surface intersects with a second surface of the buffer layer of the optical device to form a first obtuse angle
Data Source
AI summary
A display panel includes a driving backplane, an optical device layer, an adhesive layer and an optical conversion layer. The optical device layer includes optical devices each including a buffer layer and at least one light emitting unit. The buffer layer includes a first surface and a second surface. The first surface is farther away from the driving backplane than the second surface. The light-emitting unit is located on a side of the second surface away from the first surface. A buffer layer of at least one optical device further includes a side surface for connecting a first surface and a second surface. The side surface intersects with the first surface to form a first acute angle, and the side surface intersects with the second surface to form a first obtuse angle. A refractive index of the adhesive layer is less than a refractive index of the buffer layer.