Sub-Pixel Protective Pattern Layout for Low-Reflection Color Conversion
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Solution Overview
Problem
Current display devices face challenges in achieving reliable element construction and efficient light transmission, often resulting in reduced light efficiency due to reflective losses and the need for separate color control layers or substrates.
Innovation Solution
A display device design featuring a substrate with sub-pixels having first and second electrodes, light emitting elements between them, an insulating layer, a protective pattern overlapping the light emitting elements, and a bank at pixel boundaries, along with a color control layer that covers the light emitting elements' ends, minimizing reflection and allowing direct light emission into the color control layer for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional display device structure is used with separate color control layers or substrates, then color control functionality is achieved, but device thickness increases and light efficiency decreases due to reflection losses
Solution Approach 1:
The patent merges the protective pattern and color control layer into a single integrated structure. The color control layer is positioned directly on the protective pattern, eliminating the need for separate color control substrates or layers, thereby reducing device thickness and simplifying the overall structure while maintaining color control functionality
Solution Approach 2:
The protective pattern serves as an intermediary layer between the light emitting element and the color control layer. This intermediate structure reduces reflection losses by providing a gradual refractive index transition, thereby improving light efficiency without requiring additional complex anti-reflection coatings
2Reliability
If light emitting elements are covered with multiple separate layers for protection and color control, then element reliability is improved, but light efficiency decreases due to multiple interfaces causing reflection
Solution Approach 1:
The protective pattern acts as an intermediary layer with optimized refractive index between the light emitting element and the color control layer. This single intermediate layer reduces reflection losses more effectively than multiple thin layers, improving light efficiency while maintaining element protection
Solution Approach 2:
The protective pattern is formed using composite materials with specifically engineered refractive index properties. This composite structure provides both mechanical protection and optical optimization, reducing reflection losses without requiring additional separate layers for each function
3Manufacturing precision
If separate color control substrates are used above light emitting elements, then color accuracy is improved, but device thickness increases
Solution Approach 1:
The color control layer is merged with the protective pattern structure, forming an integrated component rather than a separate substrate. This integration maintains precise color control functionality while eliminating the need for additional thickness from separate color control substrates
Solution Approach 2:
The color control functionality is transitioned from a separate three-dimensional substrate to a thin two-dimensional layer integrated into the existing structure. This dimensional change maintains color control precision while dramatically reducing the thickness contribution
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 design enhances element reliability and light efficiency by reducing reflection losses and eliminating the need for separate color control layers or substrates, resulting in a thinner and more effective display device.
Implementation Method 1
The color control layer may include a base resin, and quantum dots dispersed in the base resin
Implementation Method 2
A refractive index of the protective pattern may be smaller than a refractive index of the color control layer
Data Source
AI summary
A display device and a manufacturing method thereof are provided. The display device includes a display substrate, sub-pixels on the display substrate, each of the sub-pixels including a first electrode and a second electrode on the display substrate and spaced apart from each other, light emitting elements between the first electrode and the second electrode, an insulating layer covering the light emitting elements, a protective pattern on the insulating layer and overlapping one of the light emitting elements, and a bank on the insulating layer at a boundary of one of the sub-pixels.