Display Color Element Patterning for Smaller Sub-Pixels
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Solution Overview
Problem
Conventional inkjet and photo processes limit the miniaturization of color element patterns in display apparatus, restricting the achievement of smaller sub-pixel areas necessary for high-resolution displays.
Innovation Solution
A method involving a bank layer with holes, where a color element layer is applied across the entire surface and then selectively removed outside the holes to form each color element pattern, using inorganic layers to define the pattern boundaries, allowing for smaller and more precise color element placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If conventional inkjet process or photo process is used to form color element pattern layer, then the patterning process can be completed, but the patterning area of the color element is reduced and cannot achieve smaller sub-pixel area
Solution Approach 1:
The color element layer is segmented into multiple separate color elements (first color element, second color element, third color element) positioned in different holes of the bank layer, allowing each color element to be independently formed with precise positioning while achieving overall miniaturization of the sub-pixel area
Solution Approach 2:
The patent transitions from planar patterning to three-dimensional positioning by placing color elements within holes of the bank layer at different vertical levels, enabling smaller footprint while maintaining color element integrity and positioning precision
2Measurement precision
If the area of sub-pixel is reduced to achieve high resolution, then the resolution is improved, but the patterning area of color element becomes too small for conventional processes
Solution Approach 1:
The bank layer with pre-formed holes is created before depositing the color element layer, providing predetermined positioning structures that guide color element formation. This preliminary structuring enables precise color element placement in miniaturized sub-pixels without requiring complex real-time patterning control
Solution Approach 2:
The bank layer acts as an intermediary structure between the substrate and the color elements, providing mechanical support and precise positioning features (holes) that enable formation of small color elements while maintaining manufacturing feasibility through standard deposition processes
Data Source
AI summary
A display apparatus includes a first light-emitting device, a second light-emitting device adjacent to the first light-emitting device, a third light-emitting device adjacent to the second light-emitting device, a bank layer disposed on the first light-emitting device, the second light-emitting device, and the third light-emitting device, and including a first hole overlapping the first light-emitting device, a second hole overlapping the second light-emitting device, and a third hole overlapping the third light-emitting device, a first color element disposed in the first hole, a second color element disposed in the second hole, a third color element disposed in the third hole, a first inorganic layer overlapping the first color element on the bank layer, the first inorganic layer including a first opening overlapping the second color element and a second opening overlapping the third color element, and a second inorganic layer disposed on the first inorganic layer.