Display Panel Black Glue Patterning for Higher Contrast
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Solution Overview
Problem
Mini LED display panels face challenges in achieving high contrast due to complex manufacturing processes and micronization of LED dies, which affects their performance as direct display products.
Innovation Solution
A display panel manufacturing method involving the formation of an LED die with a sacrificial layer on an array substrate, followed by coating black glue material and curing it under a predetermined temperature to form a black glue layer, while decomposing the sacrificial layer, ensuring the LED die surface is not covered, thereby improving contrast.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If black glue material is coated to cover the LED die surface, then the manufacturing process is simplified, but the contrast of the display panel deteriorates
Solution Approach 1:
The patent divides the LED die structure into multiple segments: the LED die body, a sacrificial layer coating its surface, and a black glue layer. By segmenting the surface treatment, the black glue can be applied to the sacrificial layer rather than directly to the LED die, enabling contrast improvement without complicating the manufacturing process.
Solution Approach 2:
The sacrificial layer acts as an intermediary between the LED die and the black glue material. This intermediate layer allows the black glue to be positioned precisely at the edges of the LED die while leaving the central light-emitting surface exposed, thereby improving contrast without requiring complex direct application techniques.
2Manufacturing precision
If the LED die surface is fully covered with black glue material, then the manufacturing precision is improved, but the light emission quality deteriorates
Solution Approach 1:
The sacrificial layer is applied to the LED die surface in advance, before the black glue material is coated. This preliminary action creates a predefined pattern that guides the black glue application, ensuring precise placement at the edges while automatically preserving the central light-emitting area, thus achieving both manufacturing precision and light emission quality.
Solution Approach 2:
The sacrificial layer is designed as a temporary, disposable component that is applied for the specific purpose of guiding black glue placement and then removed. This disposable element enables precise manufacturing without permanently affecting the LED die structure or light emission quality.
3Ease of operation
If conventional coating methods are used for black glue material, then the ease of operation is improved, but the contrast improvement is insufficient
Solution Approach 1:
The sacrificial layer serves as an intermediary that transforms a simple coating operation into a precision pattern formation process. By coating black glue material over the sacrificial layer, the operator achieves edge-specific coverage with conventional coating methods, and the sacrificial layer is subsequently removed to reveal the desired pattern, thereby maintaining ease of operation while achieving superior contrast improvement.
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 enhances the contrast of the display panel by preventing the black glue material from covering the LED die surface, addressing the limitations of existing mini LED technologies and improving optical performance.
Implementation Method 1
heating the black glue material and the sacrificial layer under a predetermined temperature such that the black glue material is cured to form a black glue layer
Implementation Method 2
heating the black glue material and the sacrificial layer under a predetermined temperature such that the black glue material is cured to form a black glue layer and the sacrificial layer is decomposed
Data Source
AI summary
The present application discloses a display panel and a manufacturing method thereof. The display panel manufacturing method includes forming an LED die including a sacrificial layer on an array substrate, and then coating black glue material on the array substrate. The black glue material covers the array substrate and a surface of the sacrificial layer away from the array substrate. Then, the black glue material and the sacrificial layer are heated, and the black glue material is cured to form a black glue layer such that the sacrificial layer is decomposed. The display panel and the manufacturing method thereof provided by the present application are for improving contrast of the display panel.