Sealed Tube Quantum Dot Light Conversion Device
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Solution Overview
Problem
The existing methods for manufacturing quantum dot packages face challenges such as bubble formation and cracking during the hardening process due to thermal expansion differences, and contamination issues that increase manufacturing costs and complexity, especially as display device sizes increase.
Innovation Solution
A light conversion device is developed using a sealed tube with a quantum dot material and resin film, which includes a scattering agent, and is filled with an inert gas or resin to prevent defects and simplify the manufacturing process, allowing for a rod-type quantum dot package that reduces material usage and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If quantum dot material is injected into a narrow glass tube and hardened, then a rod-type quantum dot package is formed, but bubbles and cracks occur due to thermal expansion differences
Solution Approach 1:
The patent applies preliminary action by pre-forming the quantum dot film on a separate substrate before transferring it to the final package structure. This allows the quantum dot layer to be created under controlled conditions without the thermal expansion issues that occur during in-situ hardening in narrow tubes, thereby preventing bubbles and cracks while maintaining ease of manufacture
Solution Approach 2:
The manufacturing process is segmented into separate steps: first forming the quantum dot film on a substrate, then transferring it to the package structure. This segmentation allows each step to be optimized independently, avoiding the thermal expansion problems of in-situ hardening while keeping the overall process manufacturable
2Area of stationary object
If quantum dot material is processed in larger display devices, then display size is increased, but contamination issues increase and manufacturing complexity increases
Solution Approach 1:
The patent segments the manufacturing process into modular steps that can be scaled to different display sizes. The quantum dot film is prepared separately on a substrate and then transferred to the package, allowing the same process to be applied whether the display is small or large, thereby reducing manufacturing complexity while enabling larger display areas
Solution Approach 2:
A substrate is used as an intermediary carrier for the quantum dot film during manufacturing. This intermediary allows the quantum dot material to be handled and processed in a controlled environment before final assembly, reducing contamination risks and simplifying the manufacturing process for larger display devices
3Strength
If quantum dot material is injected into a tube and hardened, then a solid package is formed, but thermal expansion differences cause cracking
Solution Approach 1:
The quantum dot film is pre-formed on a substrate under controlled conditions before being integrated into the final package structure. This preliminary formation avoids the thermal expansion shocks that occur during in-situ hardening in narrow tubes, preventing cracks while maintaining package integrity
Solution Approach 2:
A substrate serves as an intermediary that allows the quantum dot material to be processed and stabilized before final assembly. This intermediary structure prevents direct thermal expansion conflicts between the quantum dot material and the tube, eliminating crack formation while preserving package strength
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 effectively prevents bubbles and cracks, reduces manufacturing costs, and ensures uniform light conversion, enhancing the efficiency and quality of the light source unit by maintaining high color purity and uniformity in the emitted white light.
Implementation Method 1
a light conversion member within the sealed tube... a film which includes a quantum dot material and a resin... a first film which converts first light into second light and a second film which converts the first light into third light, where the first light may be blue light, the second light may be green light and the third light may be red light
Implementation Method 2
The light conversion member may be a film which includes a quantum dot material and a resin and has a band shape, and the light conversion member may further include a scattering agent
Data Source
AI summary
A light source unit includes a light guide plate which includes a front surface and a rear surface which are opposite to each other and a side between and connecting the front surface and the rear surface, a light conversion device on the side of the light guide plate; and a light source which generates and supplies light to the light conversion device. The light conversion device includes, a sealed tube, a light conversion member within the sealed tube and a space other than an area in the tube which is occupied by the light conversion member, defined in the tube.