Curved Organic EL Panel Substrate for Seamless Large Display Assembly
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Solution Overview
Problem
Conventional organic electroluminescence (EL) display technologies face challenges in producing large-sized displays due to issues with mask processing accuracy, mask alignment, and increased costs, particularly in large-sized substrates, leading to reduced aperture ratio, increased power consumption, and seam problems when combining panels.
Innovation Solution
The solution involves a configuration where panels are connected with a curved or bent base member, allowing terminals from the electrodes to be drawn out along the edges, enabling seamless connection without gaps and reducing the number of driving circuits needed, thus allowing for a larger display with reduced panel size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a conventional mask deposition method is used for large-sized substrates, then color pattern can be formed, but mask processing accuracy and mask alignment accuracy deteriorate due to the large mask size required
Solution Approach 1:
The invention divides the substrate into multiple smaller panels (e.g., four panels for a 65-inch display) that can be manufactured with conventional mask sizes. Each panel is produced separately with high precision, then assembled to form the large-sized display, avoiding the need for oversized masks while achieving the desired large screen area.
Solution Approach 2:
The invention transitions from a single large substrate approach to a multi-panel assembly approach, adding the dimension of spatial arrangement and connection. By connecting multiple panels with connection sections, the system achieves large overall size while maintaining individual panel precision through conventional manufacturing methods.
2Area of stationary object
If mask size is increased to cover large substrates, then full coverage is achieved, but mask cost increases significantly
Solution Approach 1:
The invention segments the large substrate into multiple smaller panels, each manufactured with conventional-sized masks. This eliminates the need for expensive oversized masks while achieving the same total display area through assembly of multiple panels.
3Area of stationary object
If panels are connected to form large displays, then large screen size is achieved, but seams appear between panels reducing display quality
Solution Approach 1:
The invention introduces connection sections as intermediary elements between adjacent panels. These connection sections contain non-light-emitting regions and insulating structures that electrically isolate and physically connect panels while being visually concealed, eliminating visible seams and maintaining display quality across the entire large screen.
4Illumination intensity
If aperture ratio is increased to improve luminance, then light-emitting area increases, but connection section area must be reduced which complicates panel connection
Solution Approach 1:
The invention applies different functional qualities to different regions: the light-emitting regions have high aperture ratio for maximum luminance, while the connection sections have non-light-emitting regions with insulating properties for electrical isolation and mechanical connection. This local differentiation allows optimization of each region for its specific function without compromising overall performance.
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 allows for the production of large-sized organic EL displays with improved display quality, reduced power consumption, and lower manufacturing costs by eliminating seams and optimizing panel connections.
Implementation Method 1
a base member having a flat surface on which the rectangular light-emitting section is provided and an adjacent surface that is adjacent to one of edge portions of the flat surface which extend along a pair of long sides of the rectangular light-emitting section, the base member being curved or bent in the adjacent surface in a direction in which the flat surface is warped outwards
Data Source
AI summary
Provided are an image display device in which a desired number of panels are combined so that a large light-emitting surface is realized, a panel provided in the image display device, and a method for manufacturing the panel. For this purpose, a panel (11) of the present invention includes a rectangular light-emitting section (13); a substrate (12) having a flat surface (12a′) on which the rectangular light-emitting section (13) is provided and a curved adjacent surface (12b′) that is adjacent to one of edge portions of the flat surface which extend along long sides of the rectangular light-emitting section (13); and a terminal group that is drawn out from a long side of the rectangular light-emitting section (13) and that is disposed in the adjacent surface. The panels (11) are connected to each other by linking edge portions of the flat surfaces (12a′) of the respective substrates (12) so that longitudinal directions of the respective rectangular display sections (13) are parallel to each other and so that the adjacent surface (12b′) is located on the back side of the substrate (12). In an image display section, pixels (50) are arranged in a matrix, and sub-pixels in each of the pixels (50) are aligned in a column direction of the matrix.