Photosensitive Transfer Layer for LED Light-Shielding Rectangularity
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Solution Overview
Problem
Existing light shielding materials for LED arrays suffer from light leakage at the hole end parts due to non-uniform film thickness and rectangularity issues in the light shielding layer patterns, leading to suboptimal appearance and performance.
Innovation Solution
A photosensitive transfer material with a photosensitive layer having specific transmittance and optical density characteristics, incorporating a pigment such as zirconium nitride, and a polymerizable compound, which forms a light shielding material with controlled through-holes and high rectangularity patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a light shielding layer is formed by coating methods (ink jet, spin coating, slit coating) with black ink, then the manufacturing process is simple, but density unevenness occurs due to film thickness unevenness
Solution Approach 1:
The patent applies preliminary action by forming a dry film of black ink on a temporary support before transfer. This pre-formed dry film ensures uniform thickness and density before being transferred to the substrate, eliminating the film thickness unevenness that occurs during direct coating methods while maintaining manufacturing simplicity.
2Manufacturing precision
If a light shielding layer is formed by transferring a dry film of black ink, then film thickness uniformity is improved, but light leakage occurs from hole end parts of optical elements
Solution Approach 1:
The patent applies parameter changes by optimizing the optical density of the photosensitive layer to be 3.0 or more at 550 nm wavelength. This high optical density parameter ensures sufficient light shielding capability to prevent light leakage from hole end parts while maintaining the rectangularity of the pattern. The photosensitive layer composition is specifically designed with polymerizable compounds and photopolymerization initiators to achieve this optical density.
3Object-affected harmful factors
If the photosensitive layer has high optical density to prevent light leakage, then light shielding performance improves, but the rectangularity of the pattern may deteriorate
Solution Approach 1:
The patent applies composite materials by combining a photosensitive layer containing both a polymerizable compound and a photopolymerization initiator, along with black pigment. This composite structure allows the layer to achieve high optical density (3.0 or more at 550 nm) for light leakage prevention while maintaining excellent rectangularity through controlled photopolymerization and transfer processes. The combination of these materials creates a synergistic effect that resolves the contradiction between light shielding and pattern quality.
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 provides a light shielding material with improved rectangularity and reduced light leakage, enhancing the appearance and performance of LED arrays and electronic apparatuses.
Implementation Method 1
a transmittance of the photosensitive layer to light having a wavelength of 365 nm is 0.1% to 30%, and a transmittance of the photosensitive layer to light having a wavelength of 405 nm is 0.05% to 30%
Implementation Method 2
the photosensitive layer includes a polymerizable compound and a photopolymerization initiator
Data Source
AI summary
A photosensitive transfer material including a temporary support and a transfer layer including a photosensitive layer, in which a transmittance of the photosensitive layer to light having a wavelength of 365 nm is 0.1% to 30% or a transmittance of the photosensitive layer to light having a wavelength of 405 nm is 0.05% to 30%.