Ultra-thin Polarizer Base Substrate for Display Flatness
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Solution Overview
Problem
Conventional liquid crystal display (LCD) devices face challenges in achieving a thin and flat polarizer with excellent flatness, which affects the display's performance and color accuracy due to the thickness and flatness limitations of existing polarizer substrates.
Innovation Solution
A display device is designed with a thin film transistor, pixel electrode, and a polarizer having a base substrate with a thickness ranging from 0.8 μm to 50 μm, incorporating a linear polarizer and a color conversion layer with fluorescent elements or quantum dots, along with a dichroic reflection layer and adhesion layers to enhance flatness and color representation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional polarizer substrate is used, then the polarizer can be manufactured, but the thickness and flatness are insufficient leading to poor display performance
Solution Approach 1:
The patent employs an ultra-thin base substrate (0.8-50 μm) as a flexible thin film structure to achieve both reduced thickness and maintained flatness. The thin film nature allows for better surface uniformity while minimizing thickness-related optical defects, directly resolving the contradiction between thinness and flatness requirements.
Solution Approach 2:
The patent changes the thickness parameter of the base substrate to an ultra-thin range (0.8-50 μm, preferably 1-10 μm) to simultaneously achieve reduced thickness and improved flatness. This parameter optimization resolves the technical contradiction by finding the optimal thickness range that satisfies both requirements.
2Manufacturing precision
If the distance between pixel electrode and color conversion layer is large, then manufacturing is easier, but color mixture increases reducing display quality
Solution Approach 1:
The ultra-thin base substrate (0.8-50 μm) acts as a thin film spacer that maintains a minimal yet sufficient distance between the pixel electrode and color conversion layer. This thin film structure enables precise spacing control that prevents color mixture while remaining manufacturable, resolving the contradiction between manufacturing ease and color accuracy.
Solution Approach 2:
The base substrate with pre-controlled thickness is prepared in advance before assembly, establishing the precise gap between electrodes and color conversion layer before final device assembly. This preliminary preparation ensures accurate spacing that prevents color mixture while simplifying the overall manufacturing process.
3Manufacturing precision
If the base substrate is too thin, then flatness improves, but mechanical strength decreases
Solution Approach 1:
The patent utilizes the base substrate as a flexible thin film component rather than a rigid structural element. The thin film (0.8-50 μm) provides sufficient flatness for optical performance while its flexibility compensates for reduced mechanical strength, allowing it to function within the layered display structure without requiring high structural strength.
Solution Approach 2:
The base substrate is positioned within a composite layered structure including polarizer layers, color conversion layers, and electrode structures. This composite construction provides mechanical support to the ultra-thin base substrate, enabling it to maintain both thinness for flatness and sufficient strength through the collective support of the layered composite structure.
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 results in a display device with improved flatness and color accuracy, reducing color mixture and enhancing display quality by maintaining a small distance between the pixel electrode and the color conversion layer, thus achieving better polarization efficiency and image clarity.
Implementation Method 1
a linear polarizer disposed on one surface of the base substrate
Implementation Method 2
The color conversion layer may include a fluorescent element
Implementation Method 3
The color conversion layer may include quantum dots
Implementation Method 4
The display device may further include a dichroic reflection layer disposed between the color conversion layer and the base substrate
Data Source
AI summary
A display device includes: a display substrate; an opposing substrate opposing the display substrate; and a light amount control layer disposed between the display substrate and the opposing substrate. The display substrate includes: a first substrate; a thin film transistor o disposed n the first substrate; and a pixel electrode connected to the thin film transistor. The opposing substrate includes: a second substrate; a color conversion layer disposed on the second substrate; and a first polarizer disposed on the color conversion layer. The first polarizer includes: a base substrate; and a linear polarizer disposed on one surface of the base substrate. The first polarizer opposes the pixel electrode. The one surface of the base substrate on which the linear polarizer is disposed has a flatness of about 60 nm or less.