Display Device Insulating Layer Overlap Protection
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Solution Overview
Problem
Current display devices face challenges in achieving improved light efficiency and product reliability, particularly in the design of organic light-emitting elements where the integration of power electrodes and insulating layers affects the performance and longevity of the display.
Innovation Solution
The display device incorporates a base layer with defined areas, a pixel circuit, and a light-emitting element, featuring an insulating layer made of organic material that extends and overlaps the power electrodes, along with a multi-layer encapsulation structure comprising inorganic and organic layers with varying refractive indices to enhance light emission efficiency and protect the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating layer is extended to cover the overlapping portion of the power electrode, then short-circuit prevention and reliability are improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The insulating layer is divided into multiple segments: a first insulating layer covering the pixel region and a second insulating layer extending to cover the overlapping portion of the power electrode in the non-display region. This segmentation allows the insulating structure to provide comprehensive protection without requiring complete redesign of the entire insulating system, thus improving reliability while managing complexity.
Solution Approach 2:
The insulating layer is extended from the two-dimensional pixel region into the third dimension by covering the side surface of the power electrode and extending into the non-display region. This dimensional extension ensures that the insulating layer comprehensively covers the overlapping portion of the power electrode, preventing short-circuits while maintaining a structured approach to complexity management.
2Reliability
If the insulating layer thickness is increased to ensure complete coverage, then reliability and defect prevention are improved, but the manufacturing precision requirements and production difficulty increase
Solution Approach 1:
Different thickness specifications are applied to different regions of the insulating layer. In the pixel region, the insulating layer has a thickness of 50 nm to 200 nm, while in the non-display region covering the power electrode, the thickness is increased to 200 nm to 500 nm. This local quality differentiation ensures adequate coverage and reliability where needed while avoiding excessive thickness in other areas, thus managing manufacturing precision requirements.
Solution Approach 2:
The insulating layer is applied with excessive thickness (200 nm to 500 nm) specifically in the critical region where the power electrode overlaps with the light-emitting element, rather than uniformly throughout the entire device. This partial excessive action ensures complete coverage and defect prevention in the most vulnerable area while keeping overall manufacturing complexity manageable.
3Reliability
If the encapsulation structure is added to cover the power electrode, then product reliability and lifespan are improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The encapsulation structure is merged with the existing insulating layer configuration. The second insulating layer that extends into the non-display region serves dual functions: it acts as both the insulating layer preventing short-circuits and as part of the encapsulation structure protecting the power electrode. This merging reduces the need for separate encapsulation components, thereby improving reliability while managing device complexity.
Solution Approach 2:
The second insulating layer is designed to perform multiple functions simultaneously: electrical insulation to prevent short-circuits, mechanical protection of the power electrode, and partial encapsulation to improve product lifespan. This multi-functionality reduces the overall device complexity by eliminating the need for separate dedicated encapsulation components in the non-display region.
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
This configuration enhances light emission efficiency, reduces power consumption, and improves the reliability of the display device by preventing defects such as short-circuits and burnouts, thereby extending the device's lifespan.
Implementation Method 1
an insulating layer between the base layer and the first electrode, wherein the insulating layer extends from the first area to the second area, and overlaps the first power electrode, wherein the second electrode extends from the first area toward the second area, wherein the insulating layer covers an entirety of an overlapping portion of the first power electrode overlapping the second electrode
Implementation Method 2
an encapsulation layer on the first area and the second area so as to cover the pixel, at least a portion of the first power electrode, and at least a portion of the second power electrode
Implementation Method 3
The first inorganic encapsulation layer may include a first sub-inorganic encapsulation layer having a first refractive index, a second sub-inorganic encapsulation layer on the first sub-inorganic encapsulation layer and having a second refractive index different from the first refractive index, and a third sub-inorganic encapsulation layer on the second sub-inorganic encapsulation layer and having a third refractive index different from the first and second refractive indices
Data Source
AI summary
A display device includes: a base layer with first and second areas; a pixel on the first area, wherein the pixel includes a pixel circuit and a light-emitting element, wherein the light-emitting element includes a first electrode, a light-emitting layer, and a second electrode; a first power electrode on the second area and configured to supply a first drive voltage to the pixel circuit; a second power electrode on the second area and configured to supply a second drive voltage to the second electrode; and an insulating layer between the base layer and the first electrode, wherein the insulating layer extends from the first area to the second area, and overlaps the first power electrode, wherein the second electrode extends from the first area toward the second area, and wherein the insulating layer covers an entirety of an overlapping portion of the first power electrode overlapping the second electrode.