Quantum Dot Color Conversion Roof Structure for Uniform Pixel Thickness
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Solution Overview
Problem
Display devices with color conversion panels face issues of non-uniform thickness in the color conversion layer, leading to recognition of stains and varying optical characteristics.
Innovation Solution
A display device with a uniform thickness color conversion layer, comprising first and second color conversion layers and a transmissive layer, each with quantum dots and scatterers, is manufactured using a method that includes forming a sacrificial layer, roof layers, and a partitioning wall to ensure consistent thickness and optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inkjet process is used to form color conversion layer, then manufacturing complexity is reduced, but thickness uniformity deteriorates
Solution Approach 1:
The color conversion layer is segmented into multiple discrete quantum dot layers (first color conversion layer with first quantum dots, second color conversion layer with second quantum dots, third color conversion layer with third quantum dots). Each layer is formed separately using inkjet process, allowing independent thickness control for each color conversion layer while maintaining overall thickness uniformity through the roof layer structure
Solution Approach 2:
The invention introduces a vertical dimension solution by forming a roof layer that covers the color conversion layers from above, creating a defined cavity structure. This dimensional approach allows the inkjet-dispensed quantum dots to settle into a uniform thickness configuration within the confined space, transforming the thickness uniformity problem from a horizontal spreading issue to a vertical containment solution
2Productivity
If color conversion layer thickness varies, then manufacturing process is simpler, but optical characteristics deteriorate
Solution Approach 1:
Different quantum dot layers are assigned specific local functions: the first color conversion layer converts blue light to red, the second color conversion layer converts blue light to green, and the third color conversion layer converts ultraviolet to blue. Each layer's thickness and quantum dot composition are locally optimized for its specific wavelength conversion function, ensuring consistent optical characteristics across different color channels
Solution Approach 2:
The roof layer is formed in advance to define the cavity structure before the quantum dot layers are deposited. This preliminary action establishes the thickness constraints and spatial boundaries that guide the subsequent inkjet dispensing process, ensuring that the color conversion layers achieve uniform thickness without requiring complex real-time control during manufacturing
3Manufacturing precision
If partitioning wall is added between roof layers, then color conversion layer thickness uniformity is improved, but device complexity increases
Solution Approach 1:
The partitioning wall acts as an intermediary structure between adjacent roof layers, preventing lateral spreading of quantum dot ink from one pixel region to another. This intermediary barrier ensures that each color conversion layer maintains its designated thickness within its pixel boundary without interfering with neighboring pixels, achieving thickness uniformity through spatial isolation rather than complex control mechanisms
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 achieves a uniformly thick color conversion layer, maintaining consistent optical characteristics and improving light efficiency and color purity across pixels.
Implementation Method 1
The color conversion panel may contain semiconductor nano-crystals such as quantum dots, and may convert incident light into different colors
Implementation Method 2
the first color conversion layer includes a plurality of first quantum dots and a plurality of scatterers
Data Source
AI summary
A display device and a manufacturing method thereof are provided. The display device includes a first substrate; a first color filter, a second color filter, and a third color filter that are on the first substrate; a plurality of roof layers that cover spaces that overlap the first color filter, the second color filter, and the third color filter, respectively; a first color conversion layer that is positioned in a space overlapping the first color filter; a second color conversion layer that is positioned in a space overlapping the second color filter; a transmissive layer that is positioned in a space overlapping the third color filter; and a capping layer that is positioned on the plurality of roof layers.