Display Device Light-Shielding Layer with Irregular Surface
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Solution Overview
Problem
Existing display devices face challenges in reducing external light reflection, which affects visibility and display quality.
Innovation Solution
A display device manufacturing method involving a light-shielding layer with silica particles surface-treated with a liquid-repellent material, forming a structure with irregularly arranged protrusions and concave portions to minimize external light reflection, combined with a low-reflection layer and color filter layers to enhance visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional flat light-shielding layer is used, then the manufacturing process is simple, but external light reflection is high which reduces visibility
Solution Approach 1:
The light-shielding layer is designed with an uneven surface containing protrusions and concave portions instead of a flat surface. This curvature variation scatters external light that enters the concave portions, preventing direct reflection to the viewer. The protrusions and concave portions have specific size ratios (concave portion area:protrusion area = 0.3 to 0.7) to optimize light scattering while maintaining manufacturing feasibility through photolithography processes.
2Object-affected harmful factors
If silica particles are added to the organic layer, then the uneven surface structure is formed for light reflection reduction, but the manufacturing process complexity increases
Solution Approach 1:
Silica particles are pre-dispersed into the organic layer material before coating the substrate. This preliminary incorporation allows the particles to be uniformly distributed throughout the organic layer, and subsequent baking automatically forms the uneven surface structure with protrusions and concave portions. This approach simplifies the overall process compared to adding particles after layer formation, as it combines material preparation and structure formation into integrated steps.
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 effectively reduces external light reflection, improving the visibility and display quality of the device by creating a light-shielding layer with an uneven surface and using a low-reflection layer and color filters to optimize light emission.
Implementation Method 1
performing a pre-baking process by heating the organic layer
Implementation Method 2
performing an exposure process by irradiating light onto the organic layer
Data Source
AI summary
A method of manufacturing a display device includes forming a lower structure including a substrate, forming, on the lower structure, an organic layer including a base resin and silica particles surface-treated with a liquid-repellent material, performing a pre-baking process by heating the organic layer, performing an exposure process by irradiating a light source to the organic layer, and performing a development process to form a light-shielding layer by removing a portion of the organic layer. In the development process, the silica particles surface-treated with the liquid-repellent material are removed from the organic layer.