Display Panel Quantum Dot Groove Filling for Uniform Color Conversion
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Solution Overview
Problem
The fabrication of micro-LEDs with high luminance, high pixels per inch (PPI), and full color is challenging, particularly due to issues with quantum dot light conversion layers, such as the 'coffee ring effect' in inkjet printing and degradation of quantum dots in photolithographic patterning processes.
Innovation Solution
A preparation method for a display panel involving a light-emitting substrate with a supporting base and light-emitting units, where a first film layer with grooves is aligned with a second film layer containing a draining cavity, allowing light conversion material to be injected and cured within the grooves, thereby avoiding the limitations of existing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inkjet printing process is used to fabricate quantum dot light conversion layers, then the process is simpler and more efficient, but the uniformity is poor due to the coffee ring effect
Solution Approach 1:
The patent introduces a mold as an intermediary component with cavity structures that receive and contain the quantum dot ink during printing. The mold's cavity design controls the ink distribution and prevents the coffee ring effect by providing defined boundaries and controlled drying conditions, thereby maintaining both process simplicity and uniformity
Solution Approach 2:
The patent utilizes the porous or absorbent properties of the mold material to control ink distribution. The mold cavity absorbs excess ink or controls evaporation rates in a manner that prevents coffee ring formation, ensuring uniform quantum dot layers while maintaining the simplicity of the inkjet printing process
2Manufacturing precision
If photolithographic patterning process is used to fabricate quantum dot light conversion layers, then the precision is improved for small sizes, but the light conversion efficiency decreases due to quantum dot degradation
Solution Approach 1:
The patent extracts and removes the harmful photolithographic step from the process. Instead of using photolithography that degrades quantum dots, the invention directly patterns quantum dot ink through a mold-based approach, eliminating the UV exposure that causes quantum dot degradation while maintaining precise patterning capability
Solution Approach 2:
The patent employs a disposable or single-use mold structure that is optimized for precise patterning but does not require complex photolithographic steps. The mold provides the necessary precision directly through its physical structure, avoiding the need for photolithographic agents that harm quantum dots
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 method enhances the uniformity and light conversion efficiency of quantum dot layers, addressing the uniformity and efficiency issues of previous processes.
Implementation Method 1
combining red and green quantum dot light conversion layers with blue Micro-LEDs
Data Source
AI summary
A display panel and a preparation method thereof are provided. In some embodiments, a first film layer and a second film layer are combined, light conversion material is injected from a draining cavity of the second film layer to a groove of the first film layer, the second film layer is then removed, and a light conversion layer is formed within the groove.