Black Matrix Layer on Metal Mesh for Polarizer-Less OLED Displays
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Solution Overview
Problem
The combination of direct on-cell touch (DOT) and polarizer-less (POL-less) technologies in OLED displays faces challenges with high reflectivity and low transmittance, making it difficult to develop flexible displays, as traditional polarizers cannot effectively replace polarizers without compromising user experience and production costs.
Innovation Solution
A display device structure comprising an array substrate layer, light-emitting layer, encapsulation layer, buffer layer, metal layers, and a black matrix layer, where the black matrix layer is directly disposed on the second metal layer to shorten the distance to the light-emitting layer, reduce reflectivity, and fill recesses with color resist material, omitting exposure and lift-off processes to enhance transmittance and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional polarizers are used in OLED displays, then reflectivity is reduced, but light exit loss increases by nearly 58%
Solution Approach 1:
The patent removes the polarizer component from the OLED display structure entirely, replacing it with a polarizer-less technique that uses a specific arrangement of metal mesh lines and transparent conductive layers to achieve the desired optical effects without the light-blocking polarizer film
Solution Approach 2:
The patent introduces an intermediary transparent conductive layer with specific anisotropic properties between the metal mesh line and the OLED structure, which mediates the light interaction to reduce reflectivity without causing significant light exit loss
2Illumination intensity
If polarizer-less technique with metal mesh line is used above the touch layer, then transmittance is improved, but reflectivity increases due to high reflectivity of metal mesh line to ambient light
Solution Approach 1:
The patent creates a composite structure combining the metal mesh line with a transparent conductive oxide layer having specific anisotropic electrical and optical properties, forming a composite material that simultaneously achieves low reflectivity and high transmittance
Solution Approach 2:
The patent changes the electrical and optical parameters of the transparent conductive layer by controlling its resistance anisotropy ratio and sheet resistance values, thereby adjusting the reflectivity and transmittance characteristics to optimal levels
3Reliability
If polarizer-less film is separated from electroluminescence film layer by thin film encapsulation, then touch protection is improved, but transmittance decreases due to large distance causing light absorption or blocking
Solution Approach 1:
The patent transitions from a vertical stacking approach to a planar integration approach, where the polarizer-less film is formed in the same plane as the electroluminescence layer through a specific manufacturing process, eliminating the need for thick encapsulation layers
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 configuration improves transmittance by reducing light loss and shields the metal layer from high reflectivity, ensuring low reflectivity and high transmittance while eliminating the need for exposure and lift-off processes, thereby reducing production costs and enhancing user experience.
Implementation Method 1
energy in the excited state generates photons by radiative relaxation process to release light energy
Implementation Method 2
Organic light-emitting diodes (OLEDs) are also known as organic electroluminescence displays or organic electroluminescence semiconductors
Implementation Method 3
the black matrix layer can shield the second metal layer to avoid affecting the customer experience caused by high reflectivity of the second metal layer
Data Source
AI summary
A display device and a method of manufacturing the same are disclosed. First, a black matrix layer is directly disposed on a second metal layer in such a manner that a distance between the black matrix layer and a light-emitting layer is shorten to avoid light loss, and thus transmittance is improved. Secondly, the black matrix layer can shield the second metal layer to avoid affecting the customer experience caused by high reflectivity of the second metal layer. Finally, a photoresist mask used in the etching process at the second metal layer to form a recess filed with color resist material in the prior art is replaced by the black matrix layer in such a manner that an exposure process and a lift-off process can be omitted while low reflectivity and high transmittance of the display device are ensured so as to reduce production costs.