Pixel Array Reflective Layer Protection Against Color Shift
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Solution Overview
Problem
Silver-based reflective layers in reflective or transflective display panels suffer from poor chemical resistance, heat resistance, and weather resistance, leading to issues such as decreased reflectivity, color shift, and peeling during manufacturing processes.
Innovation Solution
A pixel array substrate design that includes a silver-based reflective layer covered by a protective layer with a thickness of 30 to 80 angstroms, and a buffer layer with specific thickness ranges to enhance chemical and weather resistance, and prevent underetching and adhesion issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a silver-based reflective layer is used to achieve high reflectivity, then optical performance is improved, but chemical resistance and weather resistance deteriorate
Solution Approach 1:
The patent uses a composite structure consisting of a silver-based reflective layer combined with an organic protective layer. The silver layer provides high reflectivity while the organic layer contributes chemical resistance and weather resistance, creating a composite material system that achieves properties superior to either component alone.
Solution Approach 2:
The organic protective layer acts as an intermediary between the silver-based reflective layer and the external environment. It mediates the interaction by providing a protective barrier that prevents direct contact between the silver layer and corrosive substances, while still allowing the silver layer to perform its reflective function.
2Illumination intensity
If a silver-based reflective layer is used to achieve high reflectivity, then optical performance is improved, but adhesion to underlying layers deteriorates
Solution Approach 1:
The patent creates a composite structure where the organic protective layer serves as an adhesion promoter between the silver-based reflective layer and the underlying inorganic layers. This composite approach solves the adhesion problem while preserving the optical properties of the silver layer.
Solution Approach 2:
The organic protective layer functions as an intermediary layer that improves adhesion between the silver-based reflective layer and the underlying inorganic layers. It provides a bonding interface that is compatible with both the organic and inorganic materials, thereby strengthening the overall structure.
3Reliability
If the protective layer thickness is increased to improve chemical resistance, then reliability is improved, but optical performance deteriorates due to reflectivity decrease and color shift
Solution Approach 1:
The patent optimizes the thickness parameter of the organic protective layer to a specific range (30-80 angstroms). This parameter optimization ensures that the layer is thick enough to provide adequate chemical resistance and weather protection, while remaining thin enough to minimize its impact on the optical properties of the silver-based reflective layer.
Data Source
AI summary
A pixel array substrate including a substrate, an insulation layer, and multiple pixel structures is provided. The insulation layer is disposed on the substrate. The pixel structures are disposed on the substrate, and each includes an active device and a reflective layer. The active device is disposed between the substrate and the insulation layer. The reflective layer is disposed on the insulation layer, and includes a silver-based reflective layer and a protective layer. The silver-based reflective layer has a reflective surface. The protective layer covers the silver-based reflective layer. A thickness of the protective layer along a normal direction of the reflective surface is greater than or equal to 30 angstroms and less than or equal to 80 angstroms. Another pixel array substrate having a buffer layer is also provided.