Quantum Dot Color Conversion Layer With Low-Roughness Encapsulation
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Solution Overview
Problem
Existing display panels incorporating quantum dots face reliability issues due to surface roughness and uneven thickness of quantum dot-polymer patterns, which affect the encapsulation film's integrity and performance.
Innovation Solution
A display panel design featuring a quantum dot-polymer pattern with controlled roughness and thickness, encapsulated by an encapsulation film, where the quantum dot-polymer pattern has an average roughness less than or equal to 3% of the encapsulation film's thickness, and a maximum profile peak height less than the encapsulation film's thickness, enhancing the encapsulation and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If quantum dot-polymer patterns are formed using conventional methods, then color conversion function is achieved, but surface roughness increases and thickness becomes uneven
Solution Approach 1:
The patent applies parameter changes by controlling the average roughness (Ra) to be less than or equal to 3% of the encapsulation film thickness, and maintaining thickness uniformity within specific ranges. These quantitative parameter controls directly resolve the contradiction by ensuring both manufacturing precision and reliability are achieved simultaneously through defined thresholds.
Solution Approach 2:
The patent performs preliminary actions by pre-forming the quantum dot-polymer patterns with controlled surface properties before encapsulation, and by using partition walls to pre-define the spatial boundaries. This preliminary structuring ensures that when encapsulation occurs, the surface is already optimized for uniform coverage and stability, preventing later reliability issues.
2Quantity of substance
If the quantum dot-polymer pattern has high surface roughness, then material coverage is improved, but encapsulation quality deteriorates
Solution Approach 1:
The patent resolves this contradiction by changing the surface roughness parameter to be quantitatively controlled (Ra ≤ 3% of encapsulation film thickness). This parameter optimization ensures sufficient material coverage while maintaining encapsulation film uniformity, as the controlled roughness allows the encapsulation film to conform properly without excessive material accumulation in peaks or voids in valleys.
3Ease of manufacture
If the quantum dot-polymer pattern has uneven thickness, then manufacturing process is simplified, but luminescence stability deteriorates
Solution Approach 1:
The patent uses partition walls as a preliminary structuring element that defines the spatial boundaries and thickness profile of the quantum dot-polymer patterns. By pre-establishing these geometric constraints, the manufacturing process achieves uniform thickness through a relatively simple deposition process, while the resulting uniformity ensures luminescence stability.
Solution Approach 2:
The patent controls the thickness parameter within specific ranges (e.g., 10-100 nm or 100-500 nm depending on the embodiment) and maintains uniformity within ±10% or ±20% of the average thickness. These quantitative parameter specifications resolve the contradiction by defining a thickness window that is easy to manufacture within while ensuring stable luminescence output.
4Device complexity
If the average roughness is not controlled, then manufacturing complexity is reduced, but encapsulation reliability deteriorates
Solution Approach 1:
The patent resolves this contradiction by establishing a specific parameter threshold for average roughness (Ra ≤ 3% of encapsulation film thickness). This single parameter control provides a clear manufacturing target that balances process simplicity with encapsulation reliability, avoiding the need for complex multi-parameter optimization while ensuring sufficient encapsulation 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 controlled roughness and thickness of the quantum dot-polymer pattern improve the encapsulation film's integrity, leading to enhanced reliability and performance of the display panel.
Implementation Method 1
a color conversion layer disposed on the light emitting device array and configured to convert the emission spectrum of light emitted from the light emitting device array
Implementation Method 2
an encapsulation film on the color conversion layer
Data Source
AI summary
A display panel, a method of manufacturing the same, and an electronic device including the display panel. The display panel includes a light emitting device array including a plurality of light emitting devices, a color conversion layer disposed on the light emitting device array and converting the emission spectrum of light emitted from the light emitting device array, and an encapsulation film on the color conversion layer, wherein the color conversion layer includes a quantum dot-polymer pattern including a quantum dot-polymer composite, an average roughness (Ra) of an upper surface of the quantum dot-polymer pattern is less than or equal to about 3% of a thickness of the encapsulation film.