LED Display Pixel Density via Masking Plate QD Patterning
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Solution Overview
Problem
Current LED display manufacturing techniques face challenges in achieving high pixel density due to limited printing accuracy of quantum dot (QD) patterning, which restricts effective color conversion, especially with blue LED chips.
Innovation Solution
The implementation of a red light conversion block using quantum dots on blue or green LED chips, combined with a gallium nitride-based LED structure and a sealing material, allows for precise color conversion and patterning, reducing the complexity of QD patterning and enhancing pixel density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ink jet printing is used to form QD pattern layers on blue LED chips, then color conversion can be achieved, but printing accuracy is restricted and manufacturing precision deteriorates
Solution Approach 1:
The patent employs a masking plate with through-holes positioned over the LED chip during ink jet printing. The masking plate serves as a physical template that guides the ink jet nozzle to deposit quantum dot material only in predetermined locations. This intermediary structure enables accurate QD patterning without requiring the ink jet system itself to achieve high positioning precision, thus resolving the contradiction between ease of manufacture and manufacturing precision
Solution Approach 2:
The masking plate is prepared in advance with through-holes positioned at the exact locations where QD patterns are needed. This preliminary action of creating the physical template before printing ensures that when ink jet deposition occurs, the material is automatically placed with high precision at the correct positions, eliminating the need for complex real-time positioning control
2Productivity
If pixel density is increased, then display resolution is improved, but QD patterning difficulty increases due to restricted printing accuracy
Solution Approach 1:
When high pixel density is required, the masking plate is manufactured with correspondingly fine and dense through-hole patterns. This pre-fabricated template absorbs the complexity of high-resolution patterning, allowing the ink jet printing process to simply deposit material through the pre-defined holes. The complexity is transferred to the masking plate fabrication rather than the printing process, enabling high pixel density without proportionally increasing patterning difficulty
3Manufacturing precision
If multiple QD patterning steps are performed, then color conversion accuracy is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The masking plate is designed with multiple through-holes positioned to correspond with all the QD pattern locations needed across different color subpixels. By aligning the masking plate and performing a single ink jet printing operation, all QD patterns are deposited simultaneously in one step. This merging of multiple patterning steps into one operation significantly reduces manufacturing time while the masking plate ensures each pattern is placed with high accuracy
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 simplifies the manufacturing process, improves color conversion efficiency, and achieves high pixel density by reducing the need for multiple QD patterning steps, maintaining light stability and luminous efficiency.
Implementation Method 1
The QD pattern layer 112 may be irradiated and excited by a blue light emitted from the blue LED chip 111 to emit a red light
Data Source
AI summary
A light emitting diode (LED) display device includes a plurality of pixel units. Each of the plurality of pixel units includes a red subpixel, a green subpixel, and a blue subpixel. The red subpixel is arranged with a first LED chip, the green subpixel is arranged with a second LED chip, and the blue subpixel is arranged with a third LED chip. The first LED chip is a blue LED chip or a green LED chip. The second LED chip is the green LED chip. The third LED chip is the blue LED chip. The red subpixel is further arranged with a red light conversion block arranged on the first LED chip.