Display Microlens Transfer for Material and Process Flexibility
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Solution Overview
Problem
Current display devices face challenges in manufacturing microlenses due to material limitations and process differences, leading to poor microlens appearance and reliability issues.
Innovation Solution
A manufacturing method where microlens units are formed separately from the display structure and transferred using a fluid process, allowing independent control of microlens material and process conditions, thereby improving reliability and reducing manufacturing difficulties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If microlens is manufactured together with display structure, then manufacturing process is integrated, but material selection is limited and manufacturing precision deteriorates
Solution Approach 1:
The patent divides the manufacturing process into two independent stages: first manufacturing the display structure (substrate, light emitting unit, color filter layer), then separately manufacturing the microlens layer and transferring it to the display structure. This segmentation allows each component to be optimized independently, enabling precise control over microlens thickness and refractive index without being constrained by the display structure manufacturing process.
2Adaptability or versatility
If microlens material is constrained by display device manufacturing process, then process compatibility is improved, but material diversity is reduced
Solution Approach 1:
The patent employs preliminary action by pre-manufacturing the microlens layer on a separate substrate or template before transferring it to the final display structure. This allows the microlens to be fabricated with optimal materials and processes independent of the display device manufacturing timeline, enabling diverse material choices (such as different refractive indices or thicknesses) while maintaining process compatibility through the transfer mechanism.
3Shape
If microlens appearance is prioritized, then aesthetic quality is improved, but reliability deteriorates
Solution Approach 1:
The patent introduces an intermediary transfer process that separates the microlens fabrication from the final assembly. The microlens layer is first formed with high appearance quality on a temporary substrate, then transferred to the display structure using a controlled transfer mechanism. This intermediary step allows optimization of appearance quality during fabrication while ensuring reliability is maintained through proper transfer techniques that prevent defects and ensure consistent bonding.
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 enhances the diversity of microlens material choices and reduces defects, enabling microlenses with specific refractive indices and thicknesses, thus improving light emission efficiency and reliability.
Implementation Method 1
a microlens layer disposed on the color filter layer... the plurality of microlens units overlap the color filter layer
Data Source
AI summary
A display device includes a first substrate, a light emitting unit disposed on the first substrate and electrically connected to the first substrate, a light converting layer disposed on the light emitting unit, a color filter layer disposed on the light converting layer, a microlens layer disposed on the color filter layer, and a second substrate disposed on the microlens layer. The microlens layer includes a plurality of microlens units, and in a normal direction of the display device, the plurality of microlens units overlap the color filter layer.