Barrier Wall Undercut Structure for High-Resolution Display Patterning
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Solution Overview
Problem
Existing display technologies face challenges in achieving high resolution and process reliability due to the use of metal masks for patterning emission patterns, which limits resolution and increases defect rates, and requires a large-area mask that is costly and prone to defects.
Innovation Solution
The display device employs a barrier wall with undercut structures to physically separate light emitting elements, allowing for independent driving and patterning without a metal mask, reducing current leakage and enabling high-resolution displays with improved process reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a metal mask is used for patterning emission patterns, then the patterning process can be completed, but the resolution is limited and defect rates increase
Solution Approach 1:
The invention extracts and eliminates the metal mask from the patterning process. Instead of using a metal mask to define emission patterns, the patent uses a barrier wall structure that physically separates light emitting elements. This removal of the metal mask eliminates the associated defects and resolution limitations while maintaining the necessary patterning function through the barrier wall's geometric structure.
Solution Approach 2:
The invention replaces the mechanical metal mask system with a structural barrier wall system. The barrier wall, formed as an integral part of the pixel defining layer, provides physical separation and patterning without requiring a separate metal mask component. This substitution eliminates the mechanical limitations and defect risks associated with metal mask usage.
2Ease of manufacture
If a large-area mask is used for patterning, then emission patterns can be formed, but manufacturing costs increase and defect rates rise
Solution Approach 1:
The invention extracts and eliminates the large-area metal mask from the manufacturing process. The barrier wall structure performs the patterning function that previously required a large-area mask, thereby eliminating the costs and defect risks associated with manufacturing and using such masks.
Solution Approach 2:
The barrier wall structure serves multiple functions: it provides physical separation between light emitting elements, defines emission patterns, and eliminates the need for a separate metal mask. This multi-functionality reduces manufacturing complexity and costs while improving process reliability.
3Device complexity
If light emitting elements are not physically separated, then the structure is simpler, but current leakage occurs and driving errors happen
Solution Approach 1:
The invention segments the display structure by introducing barrier walls that physically separate light emitting elements. These barrier walls create distinct isolated regions for each emission pattern, preventing current leakage between adjacent elements while maintaining overall structural integrity. The segmentation is achieved through the barrier wall's geometric configuration rather than complex additional components.
Solution Approach 2:
The barrier wall acts as an intermediary structure between adjacent light emitting elements. It provides the necessary electrical isolation and physical separation without requiring complex additional components. The barrier wall mediates the interaction between neighboring elements, ensuring current confinement while maintaining a relatively simple overall structure.
Data Source
AI summary
A display device includes a base layer, a circuit layer disposed on the base layer, an anode disposed on the circuit layer, a pixel defining layer disposed on the circuit layer, where a light emitting opening is defined in the pixel defining layer to overlap the anode, a barrier wall disposed on the pixel defining layer, where a barrier opening is defined in the barrier wall to overlap the light emitting opening, a thin film encapsulation layer disposed over the circuit layer to cover the anode, the pixel defining layer, and the barrier wall, and a plurality of touch electrodes disposed between the circuit layer and the thin film encapsulation layer.