Spacer-Separated Display Assembly for Uniform Image Brightness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional self-luminous electronic devices suffer from uneven image brightness due to non-uniform layer elements disposed on light-emitting elements, affecting display quality.
Innovation Solution
A manufacturing method involving the use of spacers on substrates to separate and uniformize the distance between substrates, with spacers disposed on light-emitting elements to maintain consistent spacing and improve brightness uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If layer elements are disposed on light-emitting elements without spacers, then device complexity is reduced, but display quality deteriorates due to uneven image brightness
Solution Approach 1:
The patent introduces spacers as intermediary elements between the first substrate (with light-emitting elements) and the second substrate (with optical filter elements). These spacers serve as mediators that maintain a uniform distance between the substrates, ensuring consistent spacing without requiring complex alignment mechanisms or precise control during assembly.
Solution Approach 2:
The spacers are pre-formed on one of the substrates before the bonding process. This preliminary action ensures that when the substrates are bonded together, the distance uniformity is automatically established without requiring additional adjustment steps during the assembly process.
2Manufacturing precision
If spacers are added to ensure uniform spacing, then display quality improves, but manufacturing process complexity increases
Solution Approach 1:
The spacers act as intermediary elements that simplify the manufacturing process by providing a passive, self-aligning mechanism for maintaining uniform spacing. Instead of requiring active control during assembly, the spacers automatically ensure consistent distance between substrates through their physical presence and geometry.
Solution Approach 2:
The patent optimizes the dimensions of the spacers (height, width, shape) to achieve the desired spacing uniformity. By carefully selecting spacer parameters such as height ranging from 0.1 μm to 300 μm and width ranging from 0.1 μm to 300 μm, the manufacturing process becomes more robust and less sensitive to alignment variations.
3Illumination intensity
If uniform spacing is achieved through spacers, then image brightness uniformity improves, but device structure becomes more complex
Solution Approach 1:
The spacers serve as intermediary elements that directly control the optical path distance between the light-emitting elements and the optical filter elements. This uniform spacing ensures consistent light transmission and filtering, resulting in improved image brightness uniformity without requiring complex optical adjustment mechanisms.
Solution Approach 2:
The spacers are strategically disposed at specific locations (on light-emitting elements or optical filter elements) to provide localized spacing control where it is most needed for optical performance. This approach achieves uniformity in critical areas without adding unnecessary complexity throughout the entire device structure.
Data Source
AI summary
The present disclosure provides a display device and a manufacturing method thereof. The manufacturing method of the display device includes providing a first substrate, providing a second substrate, forming a plurality of spacers on the first substrate or the second substrate by a printing process, and attaching the first substrate and the second substrate to each other, wherein the first substrate and the second substrate are separated by the spacers. The first substrate includes a plurality of light-emitting elements, the second substrate includes a plurality of optical filter elements, and the light-emitting elements overlap the optical filter elements, respectively.