Self-Luminous Display Electrode Repair Around Foreign Objects
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Solution Overview
Problem
Conventional repair techniques for self-luminous display panels with thick metal layers are insufficient in increasing resistance to prevent short circuits and can cause debris scattering during laser irradiation, leading to repair failures.
Innovation Solution
A self-luminous display panel design with a high resistance portion surrounding a foreign object in the metal electrode, featuring a thickened metal layer at the outer edge, which is irradiated with a picosecond laser to increase resistance without scattering debris, and a method for manufacturing such panels by forming a ring-shaped high resistance portion around the foreign object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional laser irradiation is used to increase resistance in thick metal layers, then repair of dead points is attempted, but debris scattering occurs leading to repair failure
Solution Approach 1:
A cover layer is formed over the metal layer before laser irradiation. This cover layer acts as a protective barrier that prevents debris generated during laser processing of the thick metal layer from scattering into the organic light emitting layer, thereby enabling successful repair without contamination
Solution Approach 2:
The cover layer serves as an intermediary protective layer between the laser processing zone and the organic light emitting layer. It intercepts and contains debris particles, preventing them from reaching and damaging the organic light emitting layer during the resistance increase process
2Reliability
If laser irradiation energy is increased to penetrate thick metal layers, then resistance increase is achieved, but metal layer damage and debris generation worsen
Solution Approach 1:
The cover layer is formed in advance before laser irradiation. This preliminary protective structure allows the use of sufficient laser energy to increase resistance through the thick metal layer while the cover layer contains any resulting debris, preventing metal layer damage from causing repair failure
3Reliability
If the metal layer thickness is increased for better electrode performance, then electrical conductivity is improved, but laser repair capability deteriorates
Solution Approach 1:
The cover layer is formed as a preliminary protective structure that enables subsequent laser repair of thick metal layers. Without this cover layer, the thick metal layer would generate excessive debris during laser processing, making repair impossible. Thus, the cover layer restores repairability to thick-electrode structures
Solution Approach 2:
The cover layer acts as an intermediary that decouples the relationship between metal layer thickness and repairability. It allows thick metal layers to maintain their electrode performance while the cover layer manages the debris issue, effectively making thick electrodes repairable
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 effectively repairs dead points in self-luminous display panels by increasing electrical resistance between the foreign object and surrounding areas, preventing debris scattering and ensuring reliable repair without damaging the panel.
Implementation Method 1
irradiated with a picosecond laser to increase resistance
Implementation Method 2
material of the irradiated portion of the metal layer is melted to increase resistance
Data Source
AI summary
A self-luminous display panel 10 in which self-luminous elements 2 are arranged on a plane, wherein each of the self-luminous elements includes: a pair of electrodes 13, 20 disposed facing each other, an electrode of the pair of electrodes including a metal layer 20A; functional layers 15, 16, 17, 18, 19 including a light emitting layer 17, disposed between the pair of electrodes; and a sealing layer 21 that covers the pair of electrodes and the functional layers from a direction. The self-luminous elements include a repaired self-luminous element 2′. The repaired self-luminous element includes a foreign object FO among the functional layers. The electrode including the metal layer has a high resistance portion 201 surrounding, in plan view, an area containing the foreign object, and has a thickened portion 202 of the metal layer at an outer edge, in plan view, of the high resistance portion.