Display Device Manufacturing Method for High Luminance
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Solution Overview
Problem
Existing display devices struggle to achieve high luminance, high resolution, and high reliability, particularly in applications such as virtual reality and augmented reality, where high-definition displays are required.
Innovation Solution
A manufacturing method for a display device that involves forming first and second pixel electrodes, followed by the formation of specific films and mask layers to create layers and mask layers over the pixel electrodes. This method includes etching treatments using insulating layers as masks to expose the top surfaces of the layers and form a common electrode, with the first layer containing a blue light-emitting material and the second layer containing a material emitting light with a longer wavelength than blue light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple mask films and etching treatments are used to form separate light-emitting layers over different pixel electrodes, then manufacturing precision and reliability are improved, but device complexity and manufacturing process time increase
Solution Approach 1:
The patent divides the formation process into separate stages for different light-emitting layers. First, a blue light-emitting layer is formed using a first mask film and first etching treatment. Then, a second light-emitting layer (green or red) is formed using a second mask film and second etching treatment. This segmentation allows precise control of each layer independently, achieving high manufacturing precision while managing complexity through systematic process division.
Solution Approach 2:
The patent performs preliminary actions by forming the blue light-emitting layer and its protective structure before forming the second light-emitting layer. The first mask film and first etching treatment are completed in advance, creating a stable foundation for subsequent processing. This preliminary action ensures that the blue layer is properly established before additional layers are added, improving overall precision.
2Manufacturing precision
If multiple mask films and etching treatments are used to form separate light-emitting layers over different pixel electrodes, then manufacturing precision and reliability are improved, but manufacturing time increases
Solution Approach 1:
The patent maintains continuity of useful action by seamlessly transitioning from forming the blue light-emitting layer to forming the second light-emitting layer. The second mask film is formed over the existing structure, and the second etching treatment continues the patterning process without interrupting the manufacturing flow. This continuous approach minimizes idle time while maintaining precision.
3Productivity
If the distance between adjacent light-emitting devices is reduced to increase aperture ratio, then display quality is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by providing different protective functions at different locations. The first insulating film is formed specifically in regions between pixel electrodes to prevent short circuits, while the light-emitting layers are formed with precise patterns over each pixel electrode. This localized approach allows reduced spacing between devices while maintaining manufacturing precision through targeted protective measures.
Solution Approach 2:
The patent uses insulating films as intermediary layers between adjacent light-emitting devices. The first insulating film is formed in the regions between pixel electrodes, acting as a mediator that prevents electrical short circuits while allowing the devices to be placed closer together. This intermediary structure enables higher aperture ratios without compromising manufacturing precision.
4Reliability
If insulating films are formed between pixel electrodes to prevent short circuits, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by making the first insulating film serve multiple functions simultaneously. It prevents short circuits between adjacent pixel electrodes, provides a base layer for subsequent mask films, and defines the spacing between light-emitting devices. This multi-functional approach improves reliability while minimizing the increase in device complexity by using a single structure for multiple purposes.
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
The method enables the production of display devices with high luminance, high resolution, and high reliability, while also improving the manufacturing yield and reducing the distance between adjacent light-emitting devices, thereby increasing the aperture ratio and display quality.
Implementation Method 1
Light-emitting devices utilizing an electroluminescence (hereinafter referred to as EL) phenomenon (also referred to as EL devices or EL elements) have features such as ease of reduction in thickness and weight, high-speed response to input signals, and driving with a constant DC voltage power source
Data Source
AI summary
A display device capable of performing display at high luminance is provided. A first layer containing a first light-emitting material emitting blue light is formed into an island shape over a first pixel electrode, and then a second layer containing a second light-emitting material emitting light having a longer wavelength than blue light is formed into an island shape over a second pixel electrode. After that, an insulating layer overlapping with a region interposed between the first pixel electrode and the second pixel electrode is formed, and a common electrode is formed to cover the first layer, the second layer, and the insulating layer.