Display Substrate Lens Alignment via Segmented Definition Layer

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Solution Overview

Problem

Existing display technologies using OLEDs with nano imprint lithography face challenges in achieving accurate alignment of large-size lenses with sub-pixels due to material shrinkage, resulting in poor 3D display effects with uneven sub-pixel brightness and crosstalk.

Innovation Solution

The implementation of a display substrate with a lens definition layer and a lens structure layer, where the lens structure layer includes a plurality of lenses disposed at intervals, and the lens definition layer is positioned in gap regions between adjacent lenses, ensuring that the orthographic projection of each lens on the base contains an orthographic projection of at least one sub-pixel opening. This configuration utilizes a hydrophobic material for the lens definition layer to maintain lens independence and minimize shrinkage effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If nano imprint lithography is used to form large-size lenses, then the 3D display function is enabled, but material shrinkage causes misalignment between lenses and sub-pixels

Engineering Contradiction:

Improve3D display functionVSAvoidalignment accuracy between lenses and sub-pixels

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

A lens definition layer is introduced as an intermediary structure between the substrate and the lens structure layer. This layer includes definition regions that guide lens formation and gap regions that prevent material shrinkage from affecting lens alignment. The definition regions serve as templates that maintain precise spatial relationships with sub-pixel openings, while the gap regions isolate adjacent lenses to eliminate shrinkage-induced distortion, thereby ensuring accurate alignment despite the use of nano imprint lithography.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The lens definition layer is segmented into distinct definition regions and gap regions. The definition regions are positioned to correspond with sub-pixel openings, while gap regions are positioned between adjacent lenses. This segmentation allows the material to shrink uniformly in the gap regions without affecting the dimensional stability of the lens structures in the definition regions, thereby maintaining alignment precision.

Inventive Principle:

Principle #1Segmentation

2Measurement precision

If lenses are disposed close to each other to increase display resolution, then more sub-pixels can be covered, but lens crosstalk and uneven brightness occur

Engineering Contradiction:

Improvedisplay resolutionVSAvoidlens crosstalk and uneven sub-pixel brightness

Core Design Contradiction:

Measurement precisionVSObject-generated harmful factors

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the lens definition layer are assigned different functions: definition regions provide structural templates for lens formation with precise alignment to sub-pixels, while gap regions provide isolation between adjacent lenses. This local differentiation of quality and function allows lenses to be disposed close together for high resolution while preventing crosstalk through the isolating gap regions.

Inventive Principle:

Principle #3Local quality

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 solution achieves accurate alignment of nano imprint lithography lenses with the light emitting element, significantly improving the 3D display effect by reducing angle deviation to within the design requirement (0.008°) compared to the original deviation of 0.17°.

Implementation Method 1

a lens structure layer disposed on the circular polarizer layer, the lens structure layer including a plurality of lenses disposed at intervals

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS12207526B2Display substrate, preparation method therefor, and display apparatus

Publication Date: 2025.01.21 BOE TECHNOLOGY GROUP CO LTD

AI summary

Provided are a display substrate, a method for manufacturing a display substrate and a display apparatus. The display substrate includes a base, a drive structure layer disposed on the base, a light emitting element disposed on the drive structure layer, an encapsulation layer disposed on the light emitting element, a circular polarizer layer disposed on the encapsulation layer, and a lens definition layer and a lens structure layer disposed on the circular polarizer layer. The light emitting element includes a pixel definition layer provided with a plurality of sub-pixel openings; the lens structure layer includes a plurality of lenses disposed at intervals, the lens definition layer is disposed in a gap region between adjacent lenses, and an orthographic projection of each lens on the base contains an orthographic projection of a sub-pixel opening on the base.