Display Panel Color Conversion Capsules for Dense Quantum Dot Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The application of quantum dot materials in micro LED display panels faces challenges due to the need to mix them with photoresist and the difficulty in forming high banks to accommodate sufficient liquid, limiting light conversion efficiency and increasing manufacturing costs.
Innovation Solution
A display panel with a color conversion layer composed of multiple color conversion capsules adhered to an encapsulation material layer, eliminating the need for mixing with photoresist and allowing for a high-density color conversion layer, which improves light conversion efficiency without requiring increased bank heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If quantum dot materials are mixed with photoresist to form a color conversion layer, then the quantum dot materials can be protected from water and air, but the concentration of quantum dot materials in the mixed liquid is limited, reducing light conversion efficiency
Solution Approach 1:
The patent divides the color conversion layer into discrete color conversion capsules instead of using a continuous mixed liquid. Each capsule contains quantum dot materials encapsulated individually, allowing high concentration of quantum dots within each capsule while avoiding the dilution effect of mixing with photoresist. This segmentation enables both protection of quantum dots and high concentration maintenance.
2Quantity of substance
If the height of banks is increased to accommodate more mixed liquid, then light conversion efficiency can be improved, but the difficulty of manufacturing increases due to limitations in exposure and development technologies
Solution Approach 1:
Instead of increasing the height (vertical dimension) of banks to accommodate more color conversion material, the patent transitions to a capsule-based approach where multiple capsules are arranged in a planar array. This changes the problem from a vertical height constraint to a lateral arrangement problem, which can be solved with standard manufacturing technologies without requiring high banks.
3Reliability
If quantum dot materials are mixed with photoresist and sealed with cover plates and glue frames, then the quantum dot materials are protected from deterioration, but the manufacturing cost increases
Solution Approach 1:
The patent extracts the quantum dot materials from the photoresist mixture and places them inside individual color conversion capsules. The capsules themselves serve as the protective enclosure, eliminating the need for additional cover plates and glue frames. This extraction simplifies the overall structure while maintaining protection of the quantum dot materials.
4Area of moving object
If the nozzle size is reduced to accommodate smaller pixel sizes, then pixel density is improved, but only low concentrations of quantum dot materials can be ejected, limiting light conversion efficiency
Solution Approach 1:
The patent segments the color conversion material into discrete capsules that can be individually positioned. This segmentation allows the use of smaller nozzles for ejecting individual capsules or capsule groups while maintaining high quantum dot concentration within each capsule, thereby achieving both small pixel size and high light conversion efficiency.
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 light conversion efficiency, reduces manufacturing complexity, and enables the recycling of unused color conversion capsules, thereby lowering costs and environmental impact.
Implementation Method 1
The first color conversion capsules are configured to convert the light-emitting color of the sub-pixel structures into a first light-emitting color
Implementation Method 2
an encapsulation material layer disposed on a portion of the pattered region
Data Source
AI summary
A display panel is provided. The display panel includes a carrier having a patterned region that is disposed on the surface of the carrier and corresponds to a plurality of sub-pixel structures. The display panel also includes an encapsulation material layer disposed on a portion of the pattered region. The display panel further includes a first color conversion layer disposed on the portion of the encapsulation material layer and includes a plurality of first color conversion capsules. The first color conversion capsules are configured to convert the light-emitting color of the sub-pixel structures into a first light-emitting color. Partial surfaces of some first color conversion capsules are exposed from the encapsulation material layer.