Light Emitting Sheet Segmentation for Uniform Thickness
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Solution Overview
Problem
Display devices using light emitting sheets formed with high viscosity resin solutions suffer from aggregated particles and non-uniform thickness, leading to deteriorated color reproducibility, while low viscosity solutions are difficult to control and result in uneven thickness.
Innovation Solution
A light emitting sheet with a uniform thickness is achieved by using a resin with low viscosity, comprising a lower film, a first light emitting resin pattern layer with protrusions and grooves, and a second light emitting resin pattern layer with matching protrusions and grooves, allowing for superior color reproducibility and easier fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a light emitting resin solution having high viscosity is used to form the light emitting sheet, then the light emitting particles can be uniformly dispersed and prevented from aggregating, but the light emitting sheet cannot achieve sufficient thickness for improving color reproducibility
Solution Approach 1:
The light emitting sheet is divided into multiple layers (first light emitting resin layer, second light emitting resin layer, third light emitting resin layer) with different viscosity resins. Each layer contributes to the overall thickness while maintaining uniform particle dispersion through the segmented structure, resolving the contradiction between achieving sufficient thickness and preventing particle aggregation.
2Stability of the object's composition
If a light emitting resin solution having low viscosity is used to form the light emitting sheet, then the light emitting particles can be uniformly dispersed into the light emitting sheet, but it is difficult to control the resin solution during the process and fabricate a light emitting sheet having uniform thickness
Solution Approach 1:
The light emitting sheet is segmented into multiple layers with different viscosity characteristics. The first layer uses low viscosity resin for good particle dispersion, while subsequent layers use progressively higher viscosity resins to provide structural stability and control thickness uniformity, thereby resolving the contradiction between uniform particle dispersion and manufacturing precision.
Solution Approach 2:
The viscosity parameter of the resin solution is changed across different layers. The first light emitting resin layer uses resin with viscosity of 100-1000 cP for particle dispersion, while the second and third layers use resins with progressively higher viscosity (1000-5000 cP and 5000-10000 cP respectively) to control thickness and improve manufacturability, resolving the contradiction between uniform dispersion and thickness control.
3Quantity of substance
If a light emitting resin solution having high viscosity is used to form the light emitting sheet, then the light emitting sheet can achieve sufficient thickness for improving color reproducibility, but the light emitting particles aggregate and the color reproducibility deteriorates
Solution Approach 1:
The light emitting sheet is segmented into multiple layers where the first layer (closest to the light source) uses low viscosity resin for particle dispersion, while outer layers use progressively higher viscosity resins. This segmentation allows the sheet to achieve sufficient overall thickness for color reproducibility while preventing particle aggregation through the low viscosity first layer.
4Ease of manufacture
If a light emitting resin solution having low viscosity is used to form the light emitting sheet, then the light emitting sheet can be easily controlled during the process, but it is difficult to fabricate a light emitting sheet having uniform thickness
Solution Approach 1:
The light emitting sheet is segmented into multiple layers with increasing viscosity from the light source side outward. The first layer uses low viscosity resin (100-1000 cP) for ease of manufacturing and particle dispersion, while subsequent layers use progressively higher viscosity resins to provide thickness control and structural stability, resolving the contradiction between ease of manufacture and manufacturing precision.
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 approach enables the production of a light emitting sheet with a uniform thickness that improves color reproducibility and facilitates easier fabrication, overcoming the challenges of high and low viscosity resin solutions.
Implementation Method 1
A light emitting sheet with a uniform thickness is achieved by using a resin with low viscosity, comprising a lower film, a first light emitting resin pattern layer with protrusions and grooves, and a second light emitting resin pattern layer with matching protrusions and grooves
Data Source
AI summary
Provided are a display device and a method of fabricating the display device. The display device includes a display panel, a backlight unit, and a light emitting sheet. The backlight unit is disposed under the display panel to provide light to the display panel. The light emitting sheet is disposed between the display panel and the backlight unit. The light emitting sheet includes a lower film, a first light emitting resin pattern layer, an upper film, and a second light emitting resin pattern layer. The first light emitting resin pattern layer is disposed on the lower film and includes a plurality of first protrusions and a plurality of first grooves defined between the first protrusions. The upper film is disposed on the first light emitting resin pattern layer. The second light emitting resin pattern layer is disposed between the first light emitting resin pattern layer and the upper film.