Display Device Groove Patterns for Integrated Color Conversion
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Solution Overview
Problem
Existing display device manufacturing processes are complex and inefficient, particularly in integrating a color conversion layer without requiring a separate substrate.
Innovation Solution
The display device incorporates groove patterns in the base layer to overlap with light-emitting elements, allowing the color conversion layer to be formed within these grooves, thereby simplifying the manufacturing process and eliminating the need for a separate substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate substrate is used to provide the color conversion layer, then the color conversion layer can be properly positioned and supported, but the manufacturing process becomes complex and requires additional substrates
Solution Approach 1:
The base layer is designed to perform dual functions: serving as the structural support for light-emitting elements and simultaneously providing the color conversion layer. This merging of support and color conversion functions into a single integrated base layer eliminates the need for a separate substrate, thereby simplifying the manufacturing process and reducing device complexity
Solution Approach 2:
The base layer is engineered with multi-functionality, acting both as a mechanical support structure for mounting light-emitting elements and as a color conversion medium through integrated color conversion particles. This universal design allows one component to fulfill multiple roles that traditionally required separate substrates
2Ease of manufacture
If the color conversion layer is integrated directly on the base layer, then the manufacturing process is simplified, but the positioning and support of the color conversion layer becomes challenging
Solution Approach 1:
Color conversion particles are locally concentrated within groove patterns that are recessed into the base layer. This localized placement ensures that the color conversion layer is precisely positioned only where needed, directly beneath each light-emitting element, while maintaining the simplified integrated structure
Solution Approach 2:
The base layer is segmented with groove patterns that create distinct regions for color conversion particle placement. These grooves divide the base layer into functional zones, enabling precise positioning of color conversion material without requiring a separate substrate for alignment
3Manufacturing precision
If groove patterns are formed in the base layer, then the color conversion layer can be precisely positioned, but additional manufacturing steps are required
Solution Approach 1:
The groove patterns are pre-formed in the base layer during the substrate preparation stage, before the color conversion particles are applied. This preliminary structuring of the base layer with integrated grooves enables subsequent straightforward placement of color conversion material, improving overall manufacturing efficiency by combining structure formation and color conversion integration in a streamlined sequence
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 approach simplifies the manufacturing process by integrating the color conversion layer directly on the base layer, enabling high-resolution display devices with improved light-output efficiency.
Implementation Method 1
the color conversion layer may include: a base resin; and quantum dots dispersed in the base resin
Data Source
AI summary
A display device includes: a base layer; and light-emitting elements on a first surface of the base layer. The base layer includes groove patterns that are recessed from a second surface of the base layer, and the groove patterns overlap with the light-emitting elements, respectively.