Metasurface Display Panel Gas Layer Protection
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Solution Overview
Problem
Traditional metasurface structures require low refractive index adhesive materials for protection, which can enter between nano-pillars and affect the optical performance by altering the refractive index difference, thereby impacting the light modulation and efficiency.
Innovation Solution
A display panel design featuring a metasurface structure with a gas layer as the second medium between the substrate and cover layer, supported by pillars that maintain a refractive index difference greater than 0.7 with the nano-pillars, preventing the adhesive from contacting the nano-pillars and ensuring optimal optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If low refractive index adhesive material is coated on the surface of nano-pillars for protection, then the metasurface structure is protected, but the adhesive material enters between adjacent nano-pillars and affects the optical effect
Solution Approach 1:
The patent introduces support pillars as intermediary structures between the substrate and cover glass. These support pillars maintain a specific spacing that prevents adhesive material from contacting the optical functional layers, thereby mediating between the need for structural protection and the requirement to maintain optical performance by avoiding refractive index mismatch.
Solution Approach 2:
The patent segments the protective structure by introducing separate support pillars at corners and edges, distinguishing their functions. Corner support pillars provide structural support and spacing, while edge support pillars primarily prevent adhesive intrusion. This segmentation allows optimized protection without compromising optical performance.
2Object-affected harmful factors
If support pillars are introduced to maintain spacing between substrate and cover glass, then adhesive material is prevented from contacting nano-pillars, but the device structure becomes more complex
Solution Approach 1:
The patent applies local quality by positioning support pillars only at critical locations (corners and edges) where adhesive intrusion is most likely to occur, rather than uniformly distributing them across the entire surface. This localized approach provides effective protection while minimizing the addition of structural complexity.
3Illumination intensity
If metasurface structure is used to achieve arbitrary phase distribution, then optical performance is improved with reduced thickness, but precise control of adhesive placement becomes critical
Solution Approach 1:
The patent implements preliminary action by pre-establishing the support pillar structure before adhesive application. This preliminary structural framework proactively prevents adhesive from reaching the optical functional layers, eliminating the need for precise adhesive placement control and simplifying the manufacturing process while protecting the high-performance metasurface structure.
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 configuration maintains the optical efficiency and light modulation capabilities of the metasurface structure by avoiding the refractive index mismatch issues caused by low refractive index adhesives, enhancing the process adjustability and reducing material costs.
Implementation Method 1
a difference between the refractive index of the nano-pillars and the refractive index of the gas layer is greater than 0.7
Data Source
AI summary
This disclosure relates to a display panel, including a display panel main body and a light modulation structure on a light-emitting side of the display panel main body, where the display panel main body includes pixels; the light modulation structure includes a substrate, a first medium, a second medium, and a cover layer; the first medium includes a metasurface structure including multiple metasurface structural units arranged on a surface of the substrate close to the cover layer, the metasurface structural units are in one-to-one correspondence with the pixels and each include multiple nano-pillars; the second medium includes a gas layer filling between the substrate and the cover layer, which are spaced from each other by support pillars, and a height of the support pillars is greater than that of the nano-pillars in a direction perpendicular to the substrate. This disclosure also relates to a method for manufacturing a display panel.