Display Apparatus Insulating Layers Tapered Convex Shapes
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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 without using metal masks, which can lead to deviations in shape and position, reduced aperture ratios, and decreased manufacturing yield.
Innovation Solution
A method for fabricating a display apparatus involving the formation of island-shaped EL layers over the entire surface, using sacrificial layers and resist masks to process the light-emitting layers, and employing insulating layers with tapered and convex shapes to prevent short circuits and enhance reliability, with the insulating layers containing inorganic materials for protection and organic materials for filling depressed portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal masks are used to form island-shaped light-emitting layers, then manufacturing precision can be improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and removes the metal mask from the manufacturing process. Instead of using metal masks to form island-shaped light-emitting layers, the invention uses a different approach where the light-emitting layers are formed over the entire surface and then selectively removed in non-display regions, eliminating the need for complex metal mask fabrication and alignment processes
Solution Approach 2:
The patent inverts the conventional approach by forming light-emitting layers over the entire surface first and then removing them from non-display regions, rather than forming them only in display regions using metal masks. This inversion simplifies the manufacturing process while achieving the same result
2Illumination intensity
If aperture ratio is increased to improve display quality, then display quality improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent segments the substrate into display regions and non-display regions, with light-emitting layers formed only in display regions. This segmentation allows for increased aperture ratio while maintaining manufacturing precision by clearly defining where light-emitting layers should and should not be present through the use of insulating layers with different shapes
3Productivity
If manufacturing yield is increased by simplifying processes, then productivity improves, but display quality may deteriorate
Solution Approach 1:
The patent introduces insulating layers as intermediary structures that serve multiple functions: they define display regions, protect underlying structures, and enable the formation of light-emitting layers with appropriate shapes. These intermediary layers facilitate both high manufacturing yield and high display quality by simplifying the overall process while maintaining precision
Data Source
AI summary
A display apparatus with high display quality is provided. The display apparatus includes a first pixel, a second pixel placed to be adjacent to the first pixel, a first insulating layer, and a second insulating layer over the first insulating layer. The first pixel includes a first pixel electrode, a first EL layer covering the first pixel electrode, a third insulating layer over the first EL layer, and a common electrode over the first EL layer and the third insulating layer. The second pixel includes a second pixel electrode, a second EL layer covering the second pixel electrode, a fourth insulating layer over the second EL layer, and the common electrode over the second EL layer and the fourth insulating layer. Part of the second insulating layer overlaps with the first pixel electrode. Another part of the second insulating layer overlaps with the second pixel electrode. In a cross-sectional view of the display apparatus, a side surface of the second insulating layer has a tapered shape and a top surface thereof has a convex shape.