Display Device Gap and Microlens for High Resolution
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Solution Overview
Problem
Current display devices face challenges in achieving high-quality image display, high light extraction efficiency, high aperture ratio, high resolution, affordability, and reliability, particularly in applications like virtual reality and augmented reality where high performance is required.
Innovation Solution
A display device design incorporating adjacent light-emitting elements isolated by a gap containing gases like air, with a microlens array and protective layers to enhance light extraction and prevent color mixing, along with a manufacturing method that includes specific layer deposition and etching processes to achieve high productivity and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If light-emitting elements are placed adjacent to each other without gaps, then aperture ratio is improved, but color mixing between adjacent elements occurs degrading image quality
Solution Approach 1:
The patent introduces a gap filled with inert gas (such as nitrogen or rare gas) as an intermediary medium between adjacent light-emitting elements. This gap acts as a physical barrier that prevents color mixing while maintaining a compact structure, thus resolving the contradiction between high aperture ratio and prevention of color mixing.
2Manufacturing precision
If conventional manufacturing processes are used, then manufacturing simplicity is maintained, but manufacturing precision and productivity are insufficient for high-resolution displays
Solution Approach 1:
The patent employs preliminary actions in the manufacturing process by forming alignment marks and using photolithography patterns before depositing functional layers. The manufacturing method includes forming a lower electrode pattern, then forming an EL layer pattern with precise alignment, followed by upper electrode formation. This sequential preliminary preparation ensures high alignment precision while managing process complexity through systematic planning.
Solution Approach 2:
The patent utilizes parameter changes in the manufacturing process, specifically controlling deposition thicknesses (e.g., ITO layer thickness of 50-150 nm, Ag layer thickness of 50-200 nm), temperatures, and gas flow rates during sputtering and CVD processes. These controlled parameter changes enable precise formation of thin films and patterns, achieving high manufacturing precision for resolution of 1920×1080 or higher.
3Loss of energy
If light extraction structures are added to improve light extraction efficiency, then light extraction efficiency is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies local quality by introducing microlens structures only in specific regions where light extraction enhancement is most needed. The microlens array is positioned above the light-emitting elements with specific focal lengths (e.g., 100-500 μm) to concentrate and extract light efficiently. This localized approach improves light extraction efficiency without adding complexity to the entire device structure.
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 display of high-quality images with high light extraction efficiency, high aperture ratio, and high resolution, while being cost-effective and reliable, suitable for demanding applications like virtual and augmented reality.
Implementation Method 1
The first light-emitting element is adjacent to the second light-emitting element. The gap is provided between the first lower electrode and the first EL layer, and the second lower electrode and the second EL layer.
Implementation Method 2
A display device design incorporating adjacent light-emitting elements isolated by a gap containing gases like air, with a microlens array and protective layers to enhance light extraction
Implementation Method 3
Light-emitting elements (also referred to as EL elements or EL devices) utilizing an electroluminescence (hereinafter referred to as EL) phenomenon
Data Source
AI summary
A display device capable of displaying a high-quality image is provided. The display device includes a first light-emitting element, a second light-emitting element, and a gap. The first light-emitting element includes a first lower electrode, a first EL layer over the first lower electrode, and an upper electrode over the first EL layer. The second light-emitting element includes a second lower electrode, a second EL layer over the second lower electrode, and the upper electrode over the second EL layer. The first light-emitting element is adjacent to the second light-emitting element. The gap is provided between the first lower electrode and first EL layer and the second lower electrode and second EL layer.