Light Conversion Member with Transfer Layer for Slim Displays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display devices with wavelength conversion members, such as those using quantum dots, face challenges in protecting these particles from moisture and oxygen damage, often requiring thick barrier films that increase device thickness and manufacturing costs.
Innovation Solution
A display device design featuring a light conversion member with a transfer layer and a light conversion layer containing quantum dots, where the quantum dots are directly disposed on the transfer layer without separate barrier films, and the device is fabricated using a process where the carrier substrate is removed by adhesion force difference, allowing for a continuous attachment of optical films and display modules, and a sealing member covers the sides to prevent moisture and oxygen ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick barrier films are used to protect quantum dots from moisture and oxygen, then reliability is improved, but device thickness and manufacturing cost increase
Solution Approach 1:
The patent introduces a transfer layer as an intermediary component between the quantum dot layer and the external environment. This transfer layer serves as a protective barrier against moisture and oxygen, eliminating the need for thick barrier films. The transfer layer is applied to the carrier substrate, the quantum dot layer is formed on top of it, and then the entire structure is transferred to the final device, providing protection while maintaining device thinness.
Solution Approach 2:
The transfer layer is applied in advance to the carrier substrate before the quantum dot layer is formed. This preliminary action creates a protective barrier that is already in place when the quantum dots are deposited, preventing moisture and oxygen damage from the beginning of the manufacturing process through to the final device assembly.
2Reliability
If thick barrier films are used to protect quantum dots from moisture and oxygen, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The transfer layer acts as a cost-effective intermediary that provides protective functionality without requiring expensive thick barrier films. By using this intermediate layer, the manufacturing process avoids the cost of depositing multiple thick barrier layers while achieving the same protective effect.
Solution Approach 2:
The carrier substrate is temporarily used during manufacturing and then removed (discarded) after the transfer layer with the quantum dot layer is transferred to the final device. This allows for efficient manufacturing where the carrier substrate serves its purpose during fabrication and is then discarded, reducing overall manufacturing costs compared to using expensive barrier films.
3Ease of manufacture
If the carrier substrate is removed after forming the light conversion layer, then ease of manufacture is improved, but the quantum dots become vulnerable to moisture and oxygen
Solution Approach 1:
The transfer layer is applied in advance to the carrier substrate before the quantum dot layer is formed. This preliminary protective layer remains in place after the carrier substrate is removed, continuing to protect the quantum dots from moisture and oxygen while allowing the manufacturing process to proceed with carrier substrate removal for ease of fabrication.
Solution Approach 2:
The transfer layer serves as an intermediary protective barrier that remains after the carrier substrate is removed. It mediates between the need for easy manufacturing (carrier substrate removal) and the need for quantum dot protection, providing ongoing protection without preventing the manufacturing process.
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, reduces costs, and prevents quantum dot damage, enabling a slim, efficient display device with enhanced visibility and color reproduction quality without the need for thick barrier films.
Implementation Method 1
The protection film has an adhesion force greater than that of the transfer layer
Implementation Method 2
a wavelength conversion member including light conversion particles such as phosphors or quantum dots, are used. These light conversion particles may be capable of converting the wavelength of light generated in the backlight unit into light of desired wavelengths
Data Source
AI summary
A display device includes a backlight unit. A display module configured to display an image is disposed on the backlight unit. A light conversion member is disposed between the display module and the backlight unit. The backlight unit includes a light source unit configured to generate light and a light guide plate configured to guide the light generated by the light source unit. The light conversion member includes a transfer layer disposed on the backlight unit and a light conversion layer disposed on the transfer layer.