Quantum Dot Layer Partition Wall Segmentation for Display Manufacturing
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Solution Overview
Problem
High partition walls in display apparatus manufacturing lead to efficiency degradation and defect occurrence in the quantum dot layer, limiting the improvement of color reproducibility and emission efficiency.
Innovation Solution
A method involving the formation of first and second partition walls to define color regions, followed by the injection and volatilization of quantum dot layer materials within these regions, ensuring the quantum dot layers are formed at a controlled height, with thermal energy used for volatilization and curing, and the removal of second partition walls to optimize quantum dot layer thickness and concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high partition walls are used to increase the amount of quantum dots in the quantum dot layer, then the color reproducibility is improved, but the efficiency degradation and defect occurrence of the quantum dot layer are caused
Solution Approach 1:
The partition walls are divided into two distinct levels: first partition walls that extend from the encapsulation layer to a first height, and second partition walls that extend from the first partition walls to a second height greater than the first height. This segmentation allows the quantum dot layer to be formed in different regions with different wall heights, enabling increased quantum dot concentration in specific areas while maintaining overall layer integrity and preventing efficiency degradation.
Solution Approach 2:
Different regions of the quantum dot layer are formed with different local properties by using partition walls of different heights. The first color quantum dot layer is formed between the encapsulation layer and the first partition walls, while the second color quantum dot layer is formed between the first and second partition walls. This local quality variation allows optimized quantum dot concentration in each region without causing uniform efficiency degradation across the entire layer.
2Manufacturing precision
If high partition walls are used to increase the amount of quantum dots, then the color region definition is improved, but the defect occurrence in the quantum dot layer increases
Solution Approach 1:
The partition wall structure is segmented into first and second partition walls with different heights and functions. The first partition walls provide the primary color region definition, while the second partition walls extend locally to enable higher quantum dot concentration in specific regions. This segmentation maintains clear color region boundaries while avoiding the defects associated with uniformly high partition walls.
Solution Approach 2:
The first partition walls are formed first to establish the basic color region definitions and provide a stable foundation. Then the second partition walls are formed on top of specific first partition walls to create localized regions for enhanced quantum dot concentration. This preliminary action sequence ensures that color region definition is established before adding the complexity of varying wall heights, reducing defect occurrence.
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 approach enhances the efficiency and reduces defects in the quantum dot layer, improving color reproducibility and emission efficiency by maintaining a higher concentration of quantum dots while minimizing physical damage to partition walls.
Implementation Method 1
volatilizing a portion of a material included in the second color quantum dot layer material and a portion of a material included in the third color quantum dot layer material
Implementation Method 2
curing the second color quantum dot layer material and the third color quantum dot layer material
Data Source
AI summary
A method of manufacturing a display apparatus includes: forming a display element layer above a lower substrate, where the display element layer includes first to third display elements; forming an encapsulation layer on the display element layer; forming first partition walls on the encapsulation layer to define first to third color regions, where the first to third color regions overlap the first to third display elements, respectively, in a view in a direction perpendicular to the lower substrate; forming second partition walls on the first partition walls; forming a quantum dot layer, which includes forming a second color quantum dot layer in the second color region and forming a third color quantum dot layer in the third color region; and removing the second partition walls.