Display Apparatus Diffraction Pattern Layer Protection
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Solution Overview
Problem
Existing display apparatuses face challenges in maximizing the effective emission area ratio and minimizing visibility defects caused by foreign materials, particularly during the manufacturing process of organic light-emitting displays.
Innovation Solution
A method involving the formation of a diffraction pattern layer on a substrate, followed by bonding with a pixel layer substrate, and the use of a protection member such as a sacrificial layer or coating layer to prevent foreign material adsorption, along with subsequent cleaning and polishing steps to enhance the emission area and reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a diffraction pattern layer is formed on the substrate to increase the effective emission area ratio, then the display performance is improved, but foreign materials may be adsorbed on the diffraction pattern layer causing visibility defects
Solution Approach 1:
A protection member is introduced as an intermediary layer between the diffraction pattern layer and the external environment. This protection member prevents foreign materials from adsorbing onto the diffraction pattern layer while allowing the diffraction pattern layer to maintain its light-diffracting function. The protection member acts as a barrier that mediates the interaction between the diffraction pattern layer and foreign materials in the environment.
Solution Approach 2:
The protection member is formed on the diffraction pattern layer before the display apparatus is fully assembled and put into service. This preliminary protective action prevents foreign material adsorption from occurring in the first place, rather than attempting to remove foreign materials after they have been adsorbed. The protection is established in advance to maintain the cleanliness and visual quality of the diffraction pattern layer.
2Object-affected harmful factors
If cleaning steps are performed to remove foreign materials, then visibility defects are reduced, but the manufacturing process complexity increases
Solution Approach 1:
The protection member serves as a removable intermediary that simplifies the overall manufacturing process. Instead of performing multiple complex cleaning steps to remove foreign materials from the diffraction pattern layer, the protection member is simply formed, used during assembly, and then removed. This intermediary approach replaces complex cleaning operations with a simpler form-protection-remove sequence.
Solution Approach 2:
The protection member is extracted or removed after it has served its protective function during manufacturing. This extraction eliminates the need for complex in-situ cleaning of the diffraction pattern layer, as the protection member itself is taken out after preventing foreign material adsorption during the critical manufacturing phases. The removal step is simpler than the alternative of performing multiple cleaning operations on the delicate diffraction pattern layer.
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 method effectively increases the effective emission area ratio and minimizes foreign material-related defects, leading to improved display performance and manufacturing efficiency.
Implementation Method 1
a diffraction pattern layer diffracting light emitted from the light-emitting device
Implementation Method 2
forming a sacrificial layer on the diffraction pattern layer, and the removing of the foreign material may include removing the sacrificial layer
Data Source
AI summary
In a method of manufacturing a display apparatus, the method includes: providing a first mother substrate; forming, on the first mother substrate, a pixel layer comprising a light-emitting device; providing a second mother substrate; forming, on the second mother substrate, a diffraction pattern layer configured to diffract light emitted from the light-emitting device; forming a bonded substrate structure by bonding the first mother substrate, on which the pixel layer is formed, and the second mother substrate, on which the diffraction pattern layer is formed; forming, by cutting the bonded substrate structure, a plurality of unit substrate structures each comprising a first substrate on which the pixel layer is formed and a second substrate on which the diffraction pattern layer is formed; forming a protection member on the diffraction pattern layer; and removing a foreign material on the diffraction pattern layer with the protection member.