Edge Spacer Design for Display Device Layer Alignment
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Solution Overview
Problem
Existing display devices face challenges in manufacturing with improved reliability, particularly in ensuring proper alignment and adhesion between layers without compromising the display quality.
Innovation Solution
The proposed display device includes a first layer on a first substrate with banks protruding in the thickness direction, a color conversion layer with quantum dots, a second layer on a second substrate, a filling layer between the first and second layers, and edge spacers on the edge banks to maintain spacing and support the second layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If banks are added to the display device structure, then alignment and adhesion between layers are improved, but device complexity increases
Solution Approach 1:
The bank structure is segmented into multiple functional portions: a first bank portion extending from the first substrate, a second bank portion extending from the second substrate, and a spacer portion connecting them. This segmentation allows each portion to perform its specific function (alignment, adhesion, spacing) while maintaining overall structural integrity and managing complexity through modular design.
Solution Approach 2:
The spacer portion acts as an intermediary element between the first and second substrates. It provides controlled spacing, maintains alignment, and facilitates adhesion between the two substrates without requiring direct contact or complex bonding structures, thereby simplifying the overall assembly.
2Manufacturing precision
If edge spacers are added to space the edge bank from the second layer, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The edge spacers are formed in advance on the edge banks before the final assembly steps. This preliminary formation ensures precise spacing and alignment are established early in the manufacturing process, reducing the need for complex adjustments or corrections later and simplifying the overall manufacturing workflow.
Solution Approach 2:
The edge spacers are designed to self-align and maintain their spacing function through their structural configuration. The spacer structure inherently provides the necessary alignment features, eliminating the need for additional alignment mechanisms or complex positioning systems.
3Reliability
If filling layer is added between first and second layers, then adhesion and support are improved, but device complexity increases
Solution Approach 1:
The filling layer is merged with the bank structures to form an integrated assembly. The filling layer fills the space between the first and second substrates and is combined with the spacer and bank portions to create a unified structure that provides both adhesion and support functions, reducing the need for separate components.
Solution Approach 2:
The filling layer serves multiple functions simultaneously: it provides adhesion between substrates, mechanical support for the second layer, spacing maintenance, and alignment guidance. This multi-functionality reduces the need for additional separate components, thereby managing complexity while improving reliability.
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 configuration enhances the manufacturing reliability by ensuring proper spacing and support between layers, thereby reducing the risk of moisture permeation and improving the overall display device performance.
Implementation Method 1
a color conversion portion that includes quantum dots
Data Source
AI summary
A display device includes a first layer which is on a first substrate including a display area and includes banks protruding in a thickness direction of the first substrate and a color conversion layer in an area surrounded by the banks and including a color conversion portion that includes quantum dots, a second layer on a second substrate facing the first substrate, a filling layer between the first layer and the second layer, and a plurality of edge spacers on an edge bank which is any one of the banks.