Light Control Layer with Acute-Angle Pattern for Display Efficiency
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Solution Overview
Problem
Current display devices face challenges in enhancing light efficiency and reducing external light reflection while maintaining a simplified manufacturing process, particularly in achieving thinner and more versatile forms like curved, rollable, and foldable displays.
Innovation Solution
A display device incorporating a light control layer with a pattern layer and a cover layer, where the pattern layer overlaps pixel openings and has a higher refractive index than the cover layer, which is designed to refract light and reduce external light reflection, along with a method of manufacturing that includes forming a pre-patterned layer and applying a cover layer using plasma or extreme ultraviolet processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a light control layer with pattern layer and cover layer is added to increase light efficiency and reduce reflection, then light efficiency increases by up to 10% and external light reflection is reduced, but device complexity and manufacturing process complexity increase
Solution Approach 1:
The light control layer is divided into two distinct functional layers: a pattern layer with high refractive index (1.6 or more) that controls light direction, and a cover layer with lower refractive index (1.53 or less) that protects the pattern layer. This segmentation allows each layer to be optimized for its specific function while working together to achieve overall light efficiency improvement of up to 10% and reduced external light reflection.
Solution Approach 2:
The pattern layer is designed with specific local geometric features including a lower surface, a side surface, and an upper surface where the angle between the side surface and lower surface is an acute angle (65 degrees or less). This local geometric quality creates the refractive index effect that directs light efficiently while the cover layer provides uniform protection, allowing the system to improve light efficiency without requiring complex structures throughout the entire display device.
2Object-affected harmful factors
If additional layers (pattern layer and cover layer) are added to control light, then light efficiency increases and reflection is reduced, but manufacturing time and cost increase
Solution Approach 1:
The manufacturing process merges the formation of the pattern layer and cover layer into a single integrated light control layer structure. The pattern layer is formed first with its specific geometric features, then the cover layer is applied to cover it, creating a combined structure that reduces external light reflection while streamlining the manufacturing process compared to adding multiple separate functional layers.
Solution Approach 2:
The invention specifies precise parameter ranges for the light control layer: the angle between the side surface and lower surface of the pattern layer is 65 degrees or less, and the refractive index difference between the cover layer (1.53 or less) and pattern layer (1.6 or more) is carefully controlled. These parameter specifications enable standardized manufacturing processes that reduce variability and manufacturing time while achieving consistent light reflection reduction results.
3Length of moving object
If the light control layer is made thinner to enable thinner display designs, then device thickness is reduced and versatility is improved, but light efficiency and reflection control may be compromised
Solution Approach 1:
The light control layer uses a composite structure with two materials of different refractive indices: the pattern layer material with high refractive index (1.6 or more) for light control and the cover layer material with lower refractive index (1.53 or less) for protection. This composite material approach allows the layer to be made thinner while maintaining light efficiency because the high refractive index pattern layer provides strong light control in a reduced thickness, and the overall device thickness is reduced without sacrificing the acute angle geometry that enables effective light direction.
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 increases light efficiency by up to 10% and reduces external light reflection without the need for polarizing films or color filters, enabling thinner and more versatile display designs while simplifying the manufacturing process and reducing costs.
Implementation Method 1
a cover layer covering the pattern layer and having a refractive index lower than that of the pattern layer
Data Source
AI summary
A display device includes: a display panel including a pixel defining film and a light-emitting element, wherein the pixel defining film includes a pixel opening, wherein the light-emitting element includes a first electrode, a light-emitting layer, and a second electrode, and wherein the first electrode is at least partially exposed through the pixel opening; and a light control layer including a pattern layer and a cover layer, wherein the pattern layer overlaps the pixel opening, and wherein the cover layer covers the pattern layer and has a refractive index lower than that of the pattern layer, wherein: the pattern layer includes an upper surface, a lower surface opposite to the upper surface, and a side surface connecting the upper surface and the lower surface to each other, and an angle between the side surface and the lower surface is an acute angle.