Groove-Based Display Substrate for Defect Reduction

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Solution Overview

Problem

Existing display apparatuses face high defect rates and excessive material consumption during the manufacturing process, particularly in forming color converting portions, which affects the efficiency and reliability of the display devices.

Innovation Solution

The display apparatus is designed with a bottom substrate and a top substrate featuring grooves with reflective layers, color filter layers, and quantum dot layers, where each pixel has a dedicated emission layer, color filter, and quantum dot layer, arranged in a specific configuration to minimize material mixing and defects, with protective layers to prevent damage and contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a color converting portion is formed using conventional methods, then the display apparatus can achieve color conversion functionality, but the material consumption increases and defect occurrence rate increases

Engineering Contradiction:

Improvedefect occurrence rateVSAvoidmaterial consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The top substrate is divided into multiple grooves (first groove, second groove, third groove) corresponding to different pixel types. Each groove contains specific color filter layers and quantum dot layers tailored to its function, preventing material mixing and reducing defects during manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the top substrate have different structures: the first groove contains only color filter layers for red pixels, while the second and third grooves contain both color filter layers and quantum dot layers for green and blue pixels respectively. This localized differentiation optimizes material usage and reduces manufacturing defects.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If grooves are formed in the top substrate to separate color converting portions, then material mixing is prevented, but the device complexity increases

Engineering Contradiction:

Improvematerial separation precisionVSAvoidsubstrate structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The grooves are formed in the vertical dimension (depth of the substrate) rather than requiring complex lateral structures. By utilizing the third dimension (depth), the patent achieves effective material separation while keeping the top surface planar and the overall structure relatively simple.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If reflective layer is added to the grooves to improve light extraction, then the light emission efficiency improves, but the manufacturing steps increase

Engineering Contradiction:

Improvelight extraction efficiencyVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The reflective layer is integrated into the groove structure during the same manufacturing process where the grooves are formed, rather than being added as a separate step. This merging of functions (groove formation and reflective layer deposition) maintains manufacturing simplicity while achieving improved light extraction.

Inventive Principle:

Principle #5Merging (Combining)

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 reduces defect occurrence and material consumption, enabling a more efficient manufacturing process and improved reliability of the display apparatus by preventing material mixing and protecting sensitive components.

Implementation Method 1

a second-color quantum dot layer to convert the light in the first wavelength band into light in a second wavelength band, and a third-color quantum dot layer to convert the light in the first wavelength band into light in a third wavelength band

Methodology Applied

Scientific EffectQuantum confinement effect:

Implementation Method 2

a reflective layer on inner surfaces of the first, second, and third grooves

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS11744095B2Display apparatus with top substrate having grooves including reflective layer, color, and quantum dot layer

Publication Date: 2023.08.29 SAMSUNG DISPLAY CO LTD

AI summary

A display apparatus includes: a bottom substrate; a first light-emitable element, a second, light-emitable element, and a third light-emitable element disposed over the bottom substrate, at least one of the first, second, and third light-emitable elements including a first-color emission layer; a top substrate including a first groove, a second groove, and a third groove defined in a bottom surface thereof facing the bottom substrate, the top substrate being over the bottom substrate with the first, second, and third light-emitable elements therebetween; a reflective layer on inner surfaces of the first, second, and third grooves; a first-color color filter layer located at least partially in the first groove; each of a second-color color filter layer and a second-color quantum dot layer located at least partially in the second groove; and each of a third-color color filter layer and a third-color quantum dot layer located at least partially in the third groove.