Display Device Light Conversion Structure for High-Resolution Alignment
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Solution Overview
Problem
Existing display device manufacturing methods face limitations in achieving higher resolutions due to the inability to place micro-elements in one sub-pixel, as they cannot be easily transferred to small substrates, restricting further resolution improvement.
Innovation Solution
A method involving a driving module with at least two light emitting units and a light conversion module comprising a first and second light conversion layer, with a light blocking pattern, is used to enhance resolution by allowing precise placement and alignment of light emitting units on the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mass-transfer technique is used to transfer micro-elements to substrate, then manufacturing process is simplified, but resolution cannot be further improved due to limited space and difficulty in transferring micro-elements to small substrates
Solution Approach 1:
The patent divides the manufacturing process into separate stages: first forming micro-elements on a carrier substrate, then transferring them to the final display substrate. This segmentation allows for optimized processing at each stage, improving both resolution and manufacturability by avoiding the need to transfer micro-elements directly to small substrates during the same process step.
Solution Approach 2:
The patent introduces an intermediary carrier substrate that temporarily holds the micro-elements before transfer to the final substrate. This intermediary approach resolves the contradiction by providing a convenient platform for forming and handling micro-elements, while still enabling their transfer to the small final substrate for high-resolution display applications.
2Manufacturing precision
If micro-elements are disposed in one sub-pixel to improve resolution, then display resolution increases, but space becomes limited and manufacturing becomes difficult
Solution Approach 1:
The patent utilizes the vertical dimension by forming multiple light emitting units stacked in different layers (first light emitting units and second light emitting units at different heights). This allows multiple functional elements to occupy the same horizontal footprint, effectively increasing resolution without being constrained by limited sub-pixel planar space.
Solution Approach 2:
The patent implements a nested structure where light emitting units are arranged in multiple layers with overlapping horizontal positions. The first and second light emitting units are positioned at different vertical levels, creating a nested configuration that maximizes space utilization and enables high resolution within constrained sub-pixel areas.
3Manufacturing precision
If light emitting units are placed closer together to improve resolution, then display quality increases, but alignment precision requirements become more stringent
Solution Approach 1:
The patent performs preliminary alignment and positioning of light emitting units on the carrier substrate before transfer to the final substrate. This preliminary action establishes precise relative positions in advance, making the subsequent transfer process easier to control and ensuring accurate alignment of closely spaced light emitting units in the final high-resolution display.
Solution Approach 2:
The patent incorporates alignment marks and positioning structures that provide feedback during the transfer process. These features enable real-time adjustment and verification of light emitting unit positions, ensuring precise alignment even when units are placed close together for high-resolution display requirements.
Data Source
AI summary
A method for manufacturing a display device is provided. The method includes providing a driving module, disposing at least two light emitting units on the driving module and electrically connected to the driving module, providing a light conversion module, and disposing the light conversion module on the driving module. The light conversion module includes a first light conversion layer, a second light conversion layer, and a light blocking pattern disposed at a side of the first light conversion layer and the second light conversion layer, and an overlapping region of the first light conversion layer and the second light conversion layer is overlapped with the light blocking pattern in a top view direction.