Color Filter Formation in Light Emitting Displays
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Solution Overview
Problem
The complexity of the pixel structure and manufacturing process in organic light emitting display devices, particularly due to the large number of layers and masks required, complicates the production of color filters, increasing costs and time.
Innovation Solution
A light emitting display device structure that reduces the number of masks needed by using a light blocking layer with multiple openings and forming color filters using a combination of mask-based and inkjet methods, where one color filter is formed using a mask and the others are formed within the openings of the light blocking layer using inkjet, thereby simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mask-based methods are used to form all color filters, then manufacturing precision is improved, but device complexity and manufacturing cost increase due to the large number of masks required
Solution Approach 1:
The patent segments the color filter formation process into two parts: one color filter is formed using a mask (first color filter), while the other color filters are formed using inkjet printing without masks (second and third color filters). This segmentation reduces the total number of masks required while maintaining manufacturing precision for the mask-formed color filter.
Solution Approach 2:
The patent merges the formation of multiple color filters (second and third color filters) into a single inkjet printing process step, eliminating the need for separate mask-based formation steps for each color filter. This combining approach reduces device complexity and manufacturing cost.
2Manufacturing precision
If mask-based methods are used to form all color filters, then manufacturing precision is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent segments the color filter formation process so that only one color filter requires the time-consuming mask-based method, while the other color filters are formed more quickly using inkjet printing. This segmentation reduces total manufacturing time while preserving precision where needed.
Solution Approach 2:
The light blocking layer with pre-formed openings is used as a preliminary structure that guides the inkjet printing process, ensuring precise color filter formation without requiring additional masks. This preliminary action eliminates the need for repeated mask alignment and exposure steps.
3Manufacturing precision
If multiple masks are used to form color filters, then color filter quality is maintained, but ease of manufacture deteriorates due to complicated manufacturing process
Solution Approach 1:
The patent simplifies the manufacturing process by segmenting it into a mask-based step for one color filter and an inkjet printing step for the other color filters. This segmentation eliminates the need for multiple sequential mask operations, making the overall process easier to manufacture while maintaining color filter quality.
Solution Approach 2:
The light blocking layer with pre-formed openings acts as an intermediary structure that enables precise inkjet printing of color filters without requiring additional masks. This intermediary structure maintains color filter quality while simplifying the manufacturing process by eliminating complex mask operations.
Data Source
AI summary
A light emitting display device and its manufacturing method are presented. The device includes: a substrate; a pixel circuit unit positioned on the substrate; a light emitting diode (LED) electrically connected to the pixel circuit unit; an encapsulation layer covering the pixel circuit unit and the light emitting diode (LED); a light blocking layer disposed on the encapsulation layer and having a first opening, a second opening, and a third opening; a first color filter including a main part in the first opening and an overlapping part connecting adjacent main parts and covering the light blocking layer; a second color filter in the second opening; and a third color filter in the third opening.