Integrated Color Filter Display Structure for Thin Flexible Panels
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Solution Overview
Problem
The challenge is to create a flexible display device with enhanced visibility while minimizing thickness and maintaining flexibility, as increasing the number of functional films enhances visibility but reduces flexibility, and existing manufacturing processes are costly and time-consuming.
Innovation Solution
A method involving a display substrate divided into emission and non-emission regions, with a black matrix formed through photolithography and plasma treatment, and color patterns created using an ink-jet process directly on the encapsulation layer, where the color patterns are thinner than the black matrix and adjacent regions, and the entire structure is designed to reduce thickness and process complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the number of functional films is increased to enhance outside visibility, then visibility is improved, but the display device becomes thicker and flexibility is reduced
Solution Approach 1:
The patent combines the black matrix layer and color filter layer into a single integrated color filter layer structure. The black matrix is formed as part of the color filter layer manufacturing process, eliminating the need for separate functional films. This merging reduces the total number of layers while maintaining both the light-blocking function (visibility enhancement) and minimizing thickness accumulation.
Solution Approach 2:
The color filter layer serves multiple functions simultaneously: it provides color filtering for display quality, acts as a light-blocking layer (black matrix function) in non-emission regions, and reduces overall device thickness. By making the color filter layer multi-functional, the patent eliminates the need for additional separate functional films, thereby maintaining flexibility while enhancing visibility.
2Illumination intensity
If the number of functional films is increased to enhance outside visibility, then visibility is improved, but flexibility is reduced
Solution Approach 1:
The patent merges the black matrix and color filter into a single layer structure, reducing the total number of functional films. Fewer layers mean fewer interfaces and less cumulative thickness, which directly improves the flexibility and bendability of the display device while maintaining the visibility enhancement function.
Solution Approach 2:
The patent employs a thin-film structure for the color filter layer that is designed to be flexible. By using a integrated color filter layer with black matrix instead of multiple separate rigid functional films, the display device achieves enhanced visibility while maintaining the flexibility required for flexible display applications.
3Illumination intensity
If existing manufacturing processes are used with multiple functional films, then visibility is enhanced, but manufacturing cost and time increase
Solution Approach 1:
The patent combines the formation of the black matrix and color filter into a single manufacturing process. The color filter layer is formed first, then the black matrix is formed within specific regions of the color filter layer in the same processing sequence. This eliminates the need for separate manufacturing steps for black matrix and color filter, reducing process time and manufacturing cost while achieving enhanced visibility.
Solution Approach 2:
The patent forms the color filter layer first, then uses it as a base for forming the black matrix in subsequent steps. This preliminary action of creating the color filter layer provides a ready-made structure that simplifies later processing, reducing overall manufacturing time and complexity compared to forming separate functional films.
4Illumination intensity
If existing manufacturing processes are used with multiple functional films, then visibility is enhanced, but process cost increases
Solution Approach 1:
The patent merges the black matrix and color filter into a single integrated layer that is manufactured in one process sequence. This reduces the number of separate materials, layers, and manufacturing steps required, directly lowering material costs, processing costs, and overall manufacturing expense while maintaining enhanced visibility performance.
Solution Approach 2:
The integrated color filter layer performs multiple functions (color filtering and light blocking) that would otherwise require separate functional films. This multi-functionality reduces the total material requirements and manufacturing complexity, leading to lower production costs while achieving the same or better visibility enhancement.
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 approach results in a thinner, more flexible display device with improved visibility and reduced manufacturing costs and time, as the color filter layer is directly formed on the substrate, eliminating the need for additional optical films and enhancing the display's optical properties.
Implementation Method 1
selectively irradiating the photosensitive layer by using a mask
Implementation Method 2
providing plasma on the display substrate to surface-treat the black matrix
Implementation Method 3
drying the color solution layers using heat
Data Source
AI summary
A method of manufacturing a display device includes providing a display substrate divided into a plurality of emission regions, and a non-emission region adjacent the emission regions; forming a black matrix on the display substrate, the black matrix corresponding to the non-emission region; and forming a plurality of color patterns on the display substrate through a solution process, the plurality of color patterns corresponding to the emission regions.