Variable Thickness Intermediate Layers for Display Color Saturation
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Solution Overview
Problem
The increasing miniaturization of display components in electronic devices leads to higher occupancy and challenges in achieving uniform reflectivity and color saturation, particularly in curved display structures where traditional methods struggle to optimize the thickness of intermediate layers based on varying reflectivities across different areas.
Innovation Solution
A display apparatus and manufacturing method that divide the substrate into areas with different reflectivities, using a deposition unit with temperature-controlled deposition sources and a patterning slit sheet to form intermediate layers with varying thicknesses, comprising a common and functional layer, to optimize reflectivity and reduce color saturation non-uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional deposition methods are used to form intermediate layers, then the manufacturing process is simple, but the color saturation uniformity deteriorates due to varying reflectivities across different areas
Solution Approach 1:
The patent applies local quality by forming intermediate layers with different thicknesses in different areas of the substrate corresponding to different reflectivity regions. The deposition process is localized to specific areas with specific thickness requirements, where areas with higher reflectivity receive thinner intermediate layers and areas with lower reflectivity receive thicker intermediate layers, thereby achieving uniform color saturation across the display.
Solution Approach 2:
The patent employs dynamics by making the deposition thickness variable rather than uniform. The deposition system dynamically adjusts the thickness of the intermediate layer based on the reflectivity characteristics of different substrate areas, transforming a static uniform deposition process into a dynamic adaptive process that responds to local reflectivity conditions.
2Manufacturing precision
If uniform thickness intermediate layers are formed across the entire substrate, then the deposition process is straightforward, but the reflectivity variations cause color saturation non-uniformity
Solution Approach 1:
The patent implements local quality by tailoring the intermediate layer thickness to the specific reflectivity characteristics of each substrate area. Instead of applying a uniform thickness, the process locally adapts the thickness parameter to match the reflectivity of each region, ensuring optimal color saturation uniformity across the entire display surface.
Solution Approach 2:
The patent applies parameter changes by varying the thickness parameter of the intermediate layer based on reflectivity measurements. The deposition process modifies the thickness parameter dynamically across different substrate areas, changing from a constant parameter approach to a variable parameter approach that responds to local reflectivity conditions.
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 improves color saturation uniformity by synchronizing intermediate layer thickness with reflectivity variations across the substrate, enhancing the display's overall performance and manufacturing efficiency.
Implementation Method 1
a deposition unit configured to form at least an intermediate layer over each of plurality of areas of the base, the intermediate layers formed over the plurality of areas of the base having different thicknesses
Implementation Method 2
the deposition source is configured to deposit the deposition material over the base to form the intermediate layers with different thicknesses, by forming different temperatures according to the reflectivities of the plurality of areas of the base
Implementation Method 3
a plasma processing unit which is connected to the deposition unit and configured to perform plasma processing on the base
Data Source
AI summary
A method of manufacturing a display apparatus having a base with a plurality of pixel electrode and pixel definition layers, wherein the base is divided into a plurality of areas comprising a first area and a second area; the method comprising measuring reflectivities of the first and second areas, wherein a measured reflectivity of the first area is different from that of the second area; placing the base in a deposition chamber; and forming a first intermediate layer over a first one of the pixel electrodes in the first area; moving the base relative to the deposition unit; forming a second intermediate layer over a second one of the pixel electrodes in the second area, wherein the first intermediate layer has a first thickness and the second intermediate layer has a second thickness different from the first thickness.