Display Device Patterned Walls Wavelength Conversion Color Uniformity
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Solution Overview
Problem
Display devices using LEDs face challenges in reducing the pitch between chips, leading to uneven color mixing and increased production costs due to the 'mura effect', which affects color uniformity and human perception.
Innovation Solution
A display device design featuring a substrate with patterned walls and sub-pixels, each equipped with light-emitting elements and wavelength conversion layers, along with an optical layer that adjusts light wavelengths and absorption/reflectivity to enhance color uniformity and reduce chip count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pitch between chips in a pixel is reduced, then color uniformity requirements increase, but production costs increase due to fewer chips being usable
Solution Approach 1:
The pixel is divided into multiple sub-pixels, each containing a light-emitting element and a wavelength conversion layer. This segmentation allows for better control of light emission and color mixing at a finer scale, improving color uniformity while maintaining manufacturability through modular assembly
Solution Approach 2:
A wavelength conversion layer is introduced as an intermediary between the light-emitting element and the viewer. This layer converts the emitted light to specific wavelengths, enabling precise color control and uniform mixing without requiring tighter chip spacing, thus maintaining production efficiency
2Stability of the object's composition
If the pitch between chips in a pixel is reduced, then color mixing becomes more uniform, but the mura effect increases due to human eye sensitivity
Solution Approach 1:
Different regions of the display are equipped with specific wavelength conversion layers tailored to their function. Each sub-pixel has optimized wavelength conversion characteristics, allowing precise local control of color emission. This local optimization ensures uniform color mixing while minimizing the mura effect through targeted wavelength adjustment in each region
Solution Approach 2:
The wavelength conversion layers are designed to convert light to specific wavelengths that optimize color mixing and minimize human eye sensitivity to unevenness. By changing the optical parameters (wavelengths) rather than physical spacing, the patent achieves uniform color perception while avoiding the mura effect
3Measurement precision
If fewer chips are used to reduce pitch, then color sensitivity increases, but device complexity increases
Solution Approach 1:
The wavelength conversion layers serve multiple functions: they convert light to specific wavelengths for color generation, act as mixing media for uniform color distribution, and function as optical elements for controlling light propagation. This multi-functionality achieves high color sensitivity without adding separate components, thereby avoiding increased device complexity
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 design improves color uniformity and reduces production costs by optimizing light emission and absorption, minimizing the 'mura effect' while maintaining high color sensitivity and efficiency.
Implementation Method 1
the second wavelength conversion layer converts the light with the first wavelength into a light with a second wavelength, and the third wavelength conversion layer converts the light with the first wavelength into a light with a third wavelength
Implementation Method 2
the first optical layer reflects or absorbs the lights with the first wavelength emitted from the second and third light-emitting elements
Implementation Method 3
the first optical layer reflects or absorbs the lights with the first wavelength emitted from the second and third light-emitting elements
Data Source
AI summary
The display device includes a substrate, a patterned wall, the first, second, third sub-pixels, and an optical layer. The patterned wall is disposed on the substrate and has a plurality of openings. The first sub-pixel is disposed in one of the openings and includes a light-emitting element and a wavelength conversion layer. The second sub-pixel is disposed in one of the openings and includes a light-emitting element and a wavelength conversion layer. The third sub-pixel is disposed in one of the openings and includes a light-emitting element and a wavelength conversion layer, wherein a first distance between a top surface of the light-emitting element and a top surface of the patterned wall is about 10 um to about 100 um. The optical layer is disposed on the patterned wall and in direct contact with at least one of the first sub-pixel, the second sub-pixel, and the third sub-pixel.