Quantum Dot Display Edge Sealing via Laser Carbonization
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Solution Overview
Problem
Quantum dot display devices face reliability issues due to moisture and oxygen infiltration, leading to deterioration and defective discoloration at the cell edge portions during the scribe cutting process, which can cause separation between the quantum dot layer and barrier layers.
Innovation Solution
A display device is manufactured with a glass plate, passivation layers, a wavelength conversion layer, and an optical sheet, where the edges are sealed using a laser trim portion made of carbonized material to prevent moisture and oxygen infiltration, ensuring the quantum dot layer is thermally cured and sealed along the cell boundaries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the quantum dot layer and glass plate are increased to improve protection and durability, then the structural strength is improved, but the scribe cutting process cannot neatly cut the cell edge portions, causing separation between layers and reliability failure
Solution Approach 1:
The patent applies preliminary action by forming a groove at the cell edge portion before the scribe cutting process. This groove is created by selectively removing material to a specific depth, establishing a pre-defined cutting path that guides the scribe knife. This preliminary structural preparation enables precise cutting even through thick layers, resolving the contradiction between increased thickness for strength and cutting precision for manufacturing.
2Ease of manufacture
If the quantum dot layer is exposed to improve accessibility and processing, then the ease of manufacture is improved, but moisture and oxygen infiltration causes deterioration and discoloration, reducing reliability
Solution Approach 1:
The patent employs flexible shells and thin films by using encapsulation layers (such as barrier layers and seal structures) that conformally cover the quantum dot layer and extend to the cell edges. These thin film structures provide effective moisture and oxygen barriers while maintaining the accessibility needed for manufacturing processes, resolving the contradiction between ease of manufacture and reliability against environmental degradation.
3Reliability
If the cell edge portion is not neatly cut to maintain layer integrity, then the reliability is improved, but the separation between quantum dot layer and barrier layers occurs, causing defective discoloration
Solution Approach 1:
The patent applies preliminary action by pre-forming grooves at the cell edge portions before scribe cutting. These grooves serve as guide paths that ensure the scribe knife cuts cleanly through all layers without causing separation. By preparing this structural feature in advance, the cutting process maintains layer integrity while preventing the harmful effect of discoloration at cell edges.
Solution Approach 2:
The patent converts the potential harm of thick layers that resist clean cutting into a benefit by using the groove structure as a mechanical guide. The groove depth and positioning are designed to facilitate precise cutting through the thickness, transforming the cutting resistance from a harmful factor into a controlled process feature that ensures neat separation and prevents layer delamination.
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 effectively prevents moisture and oxygen infiltration, enhancing the reliability of the quantum dot display device by maintaining the integrity of the quantum dot layer and preventing discoloration issues, thereby improving the overall performance and longevity of the display.
Implementation Method 1
thermally curing a cell edge portion with laser for sealing the quantum dot layer
Implementation Method 2
The laser trim portion may include a carbonized material
Data Source
AI summary
A display device and a method of manufacturing the display device being capable of substantially preventing infiltration of moisture or oxygen (O2) into a quantum dot layer by scribe cutting a display panel including quantum dots and then thermally curing a cell edge portion with laser for sealing the quantum dot layer in a manufacturing process are provided. The display device includes: a glass plate; a first passivation layer disposed on the glass plate; a wavelength conversion layer disposed on the first passivation layer; a second passivation layer disposed on the wavelength conversion layer; an optical sheet disposed on the second passivation layer; a display panel disposed on the optical sheet; and a laser trim portion extending along edges of the first passivation layer, the wavelength conversion layer, and the second passivation layer.