Display Device Lens and Protective Layer Integration
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Solution Overview
Problem
Current display devices face challenges in achieving high-resolution, high-luminance, and high-reliability displays with efficient light extraction and light detection performance, particularly in applications like virtual and augmented reality, where traditional manufacturing methods lead to leakage currents, reduced aperture ratios, and decreased manufacturing yield.
Innovation Solution
A display device structure incorporating a first light-emitting device with a plano-convex lens and a protective layer, along with an insulating layer and a coloring layer, is used to enhance light extraction efficiency and prevent leakage currents, while a mask layer is employed to protect the light-emitting layer during fabrication, allowing for island-shaped light-emitting layers and shared common electrodes to increase reliability and aperture ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a microlens is used to improve light extraction efficiency, then luminance is improved, but device complexity increases due to additional layers and manufacturing steps
Solution Approach 1:
The patent combines the microlens layer with the protective layer into a single integrated structure. The protective layer serves dual functions: protecting the light-emitting device and acting as a microlens for light extraction. This merging eliminates the need for separate microlens fabrication steps while maintaining light extraction efficiency and luminance enhancement.
Solution Approach 2:
The protective layer is designed to perform multiple functions simultaneously: mechanical protection of the underlying light-emitting structure, optical focusing via microlens effect, and potential electrical insulation. This multi-functionality reduces the total number of layers required while achieving both protection and light extraction enhancement.
2Ease of manufacture
If traditional manufacturing methods are used, then ease of manufacture is maintained, but leakage currents occur and manufacturing yield decreases
Solution Approach 1:
The patent segments the light-emitting structure into isolated island-shaped light-emitting layers separated by insulating material. This segmentation prevents leakage currents between adjacent pixels by electrically isolating each light-emitting region, thereby improving manufacturing yield and device reliability while maintaining compatibility with standard fabrication processes.
Solution Approach 2:
An insulating layer is introduced as an intermediary between adjacent light-emitting devices and between the light-emitting layer and the common electrode. This intermediary layer prevents unwanted electrical conduction and leakage currents, enabling reliable manufacturing of high-resolution displays without compromising ease of manufacture.
3Illumination intensity
If the aperture ratio is increased to improve display quality, then luminance and resolution are improved, but light extraction efficiency decreases
Solution Approach 1:
The patent employs a microlens structure with a convex curved surface in the protective layer. This spherical/curved geometry focuses and directs light extraction efficiently, compensating for the reduced light extraction area caused by larger aperture ratios. The curved surface optimizes light paths to maximize extraction efficiency despite the trade-off in aperture configuration.
4Loss of energy
If a plano-convex lens structure is used to enhance light extraction, then light extraction efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
By merging the microlens formation with the protective layer deposition process, the patent eliminates the need for separate, high-precision microlens fabrication steps. The protective layer can be formed using standard spin-coating or deposition techniques, significantly reducing manufacturing precision requirements while still achieving effective light extraction enhancement through the integrated microlens 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 proposed structure achieves high-resolution and high-luminance displays with improved reliability and light detection performance, reducing leakage currents and manufacturing costs, and enabling higher aperture ratios for extended device lifespan.
Implementation Method 1
a lens over the first light-emitting device, the lens including a region overlapping with the first light-emitting device; a refractive index of the lens is higher than a refractive index of the common electrode
Implementation Method 2
a protective layer covering the lens
Implementation Method 3
a coloring layer over the protective layer
Implementation Method 4
Light-emitting devices (also referred to as EL devices or EL elements) utilizing electroluminescence (hereinafter referred to as EL)
Data Source
AI summary
A display device with high display quality is provided. The display device includes a light-emitting device; a lens provided over the light-emitting device to include a region overlapping with at least the light-emitting device; a protective layer provided to cover the lens; and a coloring layer provided over the protective layer. The light-emitting device includes an EL layer interposed between a common electrode and a pixel electrode. The EL layer contains a first light-emitting material emitting blue light and a second light-emitting material emitting light having a longer wavelength than blue light. The refractive index of the lens is higher than the refractive index of the common electrode, and the refractive index of the protective layer is lower than the refractive index of the lens.