Display Apparatus Insulating Layers Maskless Evaporation
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Solution Overview
Problem
The manufacturing of high-definition display apparatuses using organic EL devices faces challenges such as deviations in the shape and position of island-shaped light-emitting layers due to inaccuracies in metal masks, leading to reduced aperture ratio and increased manufacturing costs, especially in large-scale production.
Innovation Solution
A display apparatus structure comprising multiple light-emitting devices with insulating layers to cover end portions and side surfaces, using a method that forms island-shaped light-emitting layers without a metal mask, allowing for precise control and uniform thickness, and shared common electrodes to enhance reliability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a metal mask is used to form island-shaped light-emitting layers, then the light-emitting layers can be formed with defined shapes, but the position and shape accuracy deteriorate due to mask deviation, vapor scattering, and thermal deformation
Solution Approach 1:
The invention removes the metal mask from the vacuum evaporation system entirely, extracting the source of positioning errors. The light-emitting layers are formed by direct evaporation onto the substrate without mask intervention, eliminating mask-related deviations, warps, and alignment issues while maintaining defined island shapes through controlled evaporation parameters
Solution Approach 2:
The mechanical mask positioning system is replaced with a controlled evaporation process that uses substrate temperature control, evaporation rate regulation, and patterned evaporation zones to define light-emitting layer shapes and positions without mechanical masks, thereby eliminating mechanical positioning errors
2Productivity
If metal masks are used for manufacturing, then light-emitting layers can be formed, but manufacturing productivity decreases due to frequent mask cleaning and equipment downtime
Solution Approach 1:
The metal mask is completely removed from the manufacturing process, eliminating the need for mask cleaning, replacement, and associated equipment downtime. The continuous evaporation process can proceed without interruption for mask maintenance, significantly improving manufacturing throughput and reducing equipment idle time
Solution Approach 2:
The removal of masks enables continuous evaporation operations without interruption for mask cleaning or replacement. The manufacturing process maintains continuous useful action, with evaporation sources continuously depositing materials onto substrates without downtime for mask maintenance, thereby maximizing productivity
3Area of stationary object
If metal masks are used to form light-emitting layers, then the layers can be deposited, but the aperture ratio decreases due to vapor scattering and outline expansion
Solution Approach 1:
The mechanical mask system that causes vapor scattering and outline expansion is replaced with a controlled evaporation field that directly deposits material onto specific zones of the substrate. The evaporation process is controlled to limit scattering, producing sharp light-emitting layer outlines and maximizing the aperture ratio without mask-induced expansion
Solution Approach 2:
The evaporation process is controlled to create localized deposition zones with high material flux directly onto intended areas while minimizing scattering to surrounding regions. This local quality control ensures that light-emitting layers are formed with precise boundaries and maximum area utilization, improving aperture ratio
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 approach enables the production of high-definition display apparatuses with improved aperture ratio and reliability, reducing manufacturing complexity and costs by eliminating the need for precise metal mask alignment and frequent equipment maintenance.
Implementation Method 1
Light-emitting devices (also referred to as EL devices or EL elements) utilizing electroluminescence (hereinafter referred to as EL)
Data Source
AI summary
A high-definition or high-resolution display apparatus is provided. The display apparatus includes a first light-emitting device, a second light-emitting device, a first insulating layer, and a second insulating layer. The first light-emitting device includes a first pixel electrode, a first light-emitting layer over the first pixel electrode, and a common electrode over the first light-emitting layer. The second light-emitting device includes a second pixel electrode, a second light-emitting layer over the second pixel electrode, and the common electrode over the second light-emitting layer. Each of an end portion of the first pixel electrode and an end portion of the second pixel electrode is covered with the first insulating layer. The second insulating layer is positioned over the first insulating layer. The second insulating layer covers each of a side surface of the first light-emitting layer and a side surface of the second light-emitting layer.