Display Apparatus Dummy Pixel Insulating Layer Structure
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Solution Overview
Problem
Current display technologies face challenges in achieving high-resolution, high-quality displays with low power consumption and reliable manufacturing processes, particularly in forming island-shaped light-emitting layers with precise dimensions and uniform thickness, which is difficult with metal masks due to accuracy issues and heat deformation.
Innovation Solution
A display apparatus with a novel structure that includes a pixel portion and a dummy pixel portion, where the dummy pixels are placed outside the pixel portion and share a common electrode, using insulating layers with inorganic and organic materials to separate and protect the light-emitting layers, allowing for precise island-shaped formation and high-resolution display with reduced manufacturing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal masks are used to form island-shaped light-emitting layers, then manufacturing process is simple, but manufacturing precision deteriorates due to accuracy issues and heat deformation
Solution Approach 1:
The patent replaces the mechanical metal mask system with a photolithography-based patterning system. Instead of using physical metal masks that deform under heat and have accuracy limitations, the invention uses photoresist coatings and UV light exposure to define the island-shaped light-emitting layers. This substitution of mechanical patterning with optical patterning achieves much higher precision in forming the light-emitting layer structures while maintaining manufacturing feasibility through standard semiconductor fabrication processes.
2Illumination intensity
If aperture ratio is increased to improve display quality, then display quality improves, but manufacturing precision requirements increase making it harder to achieve
Solution Approach 1:
The photolithography process enables precise control of light-emitting layer dimensions and spacing, allowing optimization of aperture ratio for high display quality. The optical patterning method provides edge precision and dimensional control that mechanical masks cannot achieve, enabling tighter tolerances and more accurate positioning of light-emitting structures.
Solution Approach 2:
The patent employs multiple insulating layers with different material properties (inorganic and organic materials) to control the physical and chemical parameters of the light-emitting layer formation process. By adjusting layer thicknesses, material compositions, and deposition conditions, the invention optimizes both the aperture ratio for display quality and the manufacturing precision for reliable fabrication.
3Manufacturing precision
If insulating layers with inorganic and organic materials are used to separate light-emitting layers, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent divides the insulating structure into multiple functional layers: inorganic insulating layers provide barrier and structural functions, while organic insulating layers provide planarization and protective functions. This segmentation of insulating functions into distinct material layers enables precise control of light-emitting layer formation and separation, with each layer type optimized for its specific purpose in the manufacturing process.
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 solution enables the production of high-resolution displays with improved aperture ratio, reduced power consumption, and increased reliability by allowing for precise island-shaped light-emitting layer formation and efficient light extraction, while also simplifying the manufacturing process and reducing viewing angle dependence.
Implementation Method 1
By voltage application to this element, light emission can be obtained from the light-emitting organic compound
Data Source
AI summary
A display apparatus with high display quality is provided. The display apparatus includes a pixel portion and a dummy pixel portion placed outside the pixel portion and not contributing to display; the pixel portion includes a plurality of light-emitting devices; each of the light-emitting devices includes a pixel electrode, a first layer that includes a light-emitting layer, and a common electrode; the first layers of adjacent pixels of a plurality of pixels are separated by a first insulating layer containing an inorganic material and a second insulating layer containing an organic material; the side surface of the first layer includes a region in contact with the first insulating layer; the second insulating layer is over and in contact with the first insulating layer and is placed below the common electrode; the dummy pixel portion includes a plurality of dummy light-emitting devices; each of the dummy light-emitting devices includes a conductive layer and a second layer; the side surface of the second layer includes a region in contact with the first insulating layer; the second insulating layer is over and in contact with the first insulating layer; the conductive layer contains the same material as the pixel electrode; and the second layer contains the same material as the light-emitting layer.