Encapsulation Layer Polishing for Uniform Multi-Screen Displays
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Solution Overview
Problem
Conventional display devices using semiconductor light emitting devices face challenges in reducing the thickness of the coating layer, leading to total reflection and heterogeneity in multi-screen displays, which affects image quality and manufacturing yield.
Innovation Solution
A display device with a substrate and semiconductor light emitting devices, featuring a reduced-height encapsulation layer formed by a lapping process, followed by a film layer, to minimize total reflection and allow reworking of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the coating layer thickness is reduced to less than a predetermined thickness, then the display device achieves a slimmer size, but total reflection occurs in the edge area causing light extinction or amplification and heterogeneity in multi-screen displays
Solution Approach 1:
The patent applies local quality by forming a polishing pattern only in the edge area of the coating layer, while the central area maintains its original structure. This localized modification changes the optical properties specifically where total reflection occurs, allowing thin coating layers without compromising overall image quality consistency.
Solution Approach 2:
The patent converts the harmful total reflection phenomenon into a benefit by introducing a polishing pattern that controls light reflection. The polishing pattern transforms unwanted total reflection into controlled light scattering or reflection, eliminating light extinction/amplification issues while maintaining the thin coating layer structure.
2Ease of manufacture
If conventional molding or hot melt process is used to form the coating layer, then the coating layer can be formed, but it is difficult to reduce the thickness to less than a predetermined thickness
Solution Approach 1:
The patent replaces the conventional molding or hot melt process with a new formation method that allows precise thickness control. The coating layer is formed and then selectively polished using mechanical removal, enabling thickness reduction to below predetermined levels while maintaining formation feasibility.
Solution Approach 2:
The patent forms the coating layer with an initial thickness that is then reduced through selective polishing. This preliminary formation followed by precision removal allows the final thickness to be controlled below predetermined levels while ensuring complete coverage during the formation stage.
3Productivity
If the coating layer is not normally formed using conventional processes, then manufacturing defects occur, but it is virtually impossible to re-form the coating layer
Solution Approach 1:
The patent enables recovery of defective coating layers by selectively removing the polishing pattern through chemical or mechanical means, allowing reformation of the coating layer. This discards the defective polished surface and recovers the underlying coating structure for correction.
4Area of stationary object
If a multi-screen display device is implemented by connecting multiple semiconductor light emitting device display devices, then large area display is achieved, but total reflection in edge areas creates disconnection and heterogeneity reducing immersion
Solution Approach 1:
The patent applies local quality by forming polishing patterns specifically in the edge areas of each display module. This localized treatment addresses the total reflection issue at boundaries without affecting the central display areas, ensuring image homogeneity across the entire multi-screen display while maintaining large display area.
Solution Approach 2:
The patent segments the coating layer treatment by applying polishing patterns only to edge regions rather than the entire coating layer. This segmentation allows different optical properties in edge versus central areas, solving the heterogeneity problem in multi-screen displays while preserving the overall large display area.
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 solution reduces coating layer thickness, preventing total reflection and enhancing image quality in multi-screen displays while maximizing manufacturing yield and reducing costs.
Implementation Method 1
a lapping process may be performed on the encapsulation layer exceeding a preset height from among the encapsulation layers
Implementation Method 2
total reflection may occur in the edge area of each unit display device. Due to the total reflection phenomenon, light of a specific color is extinguished or amplified
Data Source
AI summary
Display device according to an embodiment of the present invention includes a substrate, a plurality of semiconductor light emitting devices formed on the upper surface of the substrate, and a coating layer formed on the substrate. The coating layer includes an encapsulation layer formed at a predetermined height from the upper surface of the substrate and covering the plurality of semiconductor light emitting devices, and a film layer formed on the upper surface of the encapsulation layer. A polishing pattern is formed on the upper surface of the encapsulation layer.