Display Panel Structure With Moving Black Particles for Higher Contrast
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Solution Overview
Problem
Conventional mini-LED and micro-LED display panel manufacturing processes face issues such as low brightness, uneven sealing surfaces, low contrast ratios, complex process flow, and low efficiency due to the use of black adhesives that block light or have uneven surfaces.
Innovation Solution
A display panel design featuring a light-emitting layer with adjustable black photosensitive particles that move between gaps based on light exposure, utilizing a structure with transparent substrates and a sealant frame to enhance brightness and contrast by redistributing particles in bright and dark states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If black adhesive is used to seal the entire surface, then sealing is achieved, but brightness decreases due to light blocking and surface unevenness
Solution Approach 1:
The sealing function is segmented from the light-emitting areas. Instead of covering the entire surface with black adhesive, the patent uses light-shielding units only in the gap regions between light-emitting units, allowing light to pass through the light-emitting areas while maintaining sealing in the gap regions.
Solution Approach 2:
The black adhesive is extracted from the light-emitting areas and relocated to only the gap regions. This extraction allows the light-emitting areas to maintain their full brightness while the gap regions continue to provide sealing functionality through the light-shielding units.
2Reliability
If black adhesive is disposed between adjacent LEDs with transparent epoxy layer on entire surface, then sealing is attempted, but surface flatness and contrast ratio deteriorate
Solution Approach 1:
The sealing structure is segmented into discrete light-shielding units positioned in gap regions rather than a continuous black adhesive layer. This segmentation allows each light-shielding unit to be independently positioned and sized, improving surface flatness while maintaining sealing effectiveness.
Solution Approach 2:
Light-shielding units are applied locally only in the gap regions where sealing is needed, rather than covering the entire surface. This local application maintains surface flatness in light-emitting areas while providing necessary sealing in gap regions, improving overall surface quality and contrast ratio.
3Ease of manufacture
If conventional SMT printing process is used, then LED transfer is achieved, but process complexity and manufacturing time increase
Solution Approach 1:
The light-shielding unit formation process is merged with the existing SMT printing process. The light-shielding units are formed as part of the same manufacturing flow, combining multiple functions into a single process sequence and reducing overall process complexity.
Solution Approach 2:
The light-shielding units serve multiple functions: they provide sealing in gap regions, maintain surface flatness, and enable contrast enhancement. This multi-functionality reduces the need for separate dedicated components and processes, simplifying the overall manufacturing approach.
4Reliability
If black adhesive is used for sealing, then sealing is achieved, but manufacturing efficiency decreases due to complex processes
Solution Approach 1:
By segmenting the sealing function to only gap regions rather than entire surfaces, the patent reduces the amount of black adhesive material needed and simplifies the application process. This segmentation approach maintains necessary sealing while improving manufacturing efficiency through reduced material usage and simpler processing.
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
Increases brightness at light-emitting units and decreases brightness at gaps, thereby enhancing display contrast and simplifying the manufacturing process by eliminating the need for full-surface adhesives, thus improving overall panel quality and efficiency.
Implementation Method 1
the adjustment structure comprises a plurality of black photosensitive particles in the adjustment structure; wherein when the display panel is in a bright state, light emitted from the light-emitting units illuminate the black photosensitive particles, and the black photosensitive particles move to positions corresponding to the first gaps
Data Source
AI summary
The present invention provides a display panel and a manufacturing method of the display panel. In the present invention, an adjustment structure is arranged on the light-emitting layer, and black photosensitive particles are arranged in the adjustment structure. When the display panel is in a bright state, light emitted by the light-emitting unit illuminates the black photosensitive particles, and the black photosensitive particles move toward positions corresponding to first gaps. Therefore, brightness at the light-emitting units is increased, and brightness at the first gaps is decreased. Accordingly, a contrast ratio of the display panel is increased.