Light Conversion Member Fabrication Yield via Substrate Segmentation
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Solution Overview
Problem
The existing methods for fabricating light conversion members using glass substrates often result in breakage during the laser cutting process, leading to inefficiencies and reduced yield in producing bar-type light conversion members for display devices.
Innovation Solution
A method involving the formation of grooves on a first substrate, connection members on the top surface, and corresponding connection members on a second substrate, which are then bonded and cut using lasers to minimize breakage and enhance the fabrication process, including the use of frit glass and quantum dot resin for light conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a plurality of tubes are disposed on a first glass substrate and a second glass substrate is bonded onto the first glass substrate, then multiple light conversion members can be fabricated simultaneously, but the glass substrates frequently break during laser cutting
Solution Approach 1:
The patent divides the substrate processing into separate stages: first cutting the second substrate into individual units, then bonding them to the first substrate, and finally cutting the first substrate. This segmentation reduces the risk of breakage by avoiding simultaneous cutting of both bonded substrates.
Solution Approach 2:
The second substrate is cut into individual light conversion member units before bonding to the first substrate. This preliminary action allows the second substrate to be processed while standalone, reducing the risk of breakage during subsequent bonding and final cutting operations.
2Ease of manufacture
If laser cutting is used to separate light conversion members from bonded glass substrates, then individual light conversion members can be obtained, but the cutting process causes frequent substrate breakage
Solution Approach 1:
The patent segments the cutting process into two distinct stages: first cutting the second substrate before bonding, then cutting the first substrate after bonding. This segmentation allows each cutting operation to be performed on a more stable configuration, reducing breakage risk.
Solution Approach 2:
The second substrate is pre-cut into individual units before bonding to the first substrate. This preliminary cutting action simplifies the final separation process and reduces the complexity and risk of the bonding-cutting operation.
3Productivity
If multiple cutting operations are performed on bonded glass substrates, then individual light conversion members are produced, but the manufacturing process becomes complex and yield decreases
Solution Approach 1:
The manufacturing process is segmented into distinct stages with clear separation of cutting operations. The first cutting stage processes the second substrate independently, and the second cutting stage processes the first substrate after bonding, simplifying process control and reducing complexity.
Solution Approach 2:
The second substrate is pre-processed and cut into individual units before bonding. This preliminary action reduces the complexity of the final assembly and cutting operations, improving overall process efficiency and yield.
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 reduces the frequency of substrate breakage during cutting, simplifies the manufacturing process, and improves the yield of light conversion members by optimizing the laser cutting technique and material bonding.
Implementation Method 1
an operation in which the first and second glass substrates bonded to each other are cut may be performed by using a laser
Implementation Method 2
The light conversion member may convert blue light into white light
Data Source
AI summary
A display devices include: a light source configured to emit first light; a light conversion member configured to convert the first light into second light; and a display panel for displaying an image using the second light, wherein the light conversion member includes: a first unit substrate defined a groove etched by a predetermined depth; a second unit substrate disposed to face the first unit substrate; a first connection member having a closed loop shape surrounding the groove and disposed on the first unit substrate; a second connection member bonded to the first connection member and disposed on the second unit substrate to overlap the first connection member; and a quantum dot member disposed in the groove and configured to receive the first light and configured to convert the first light into the second light.