Display Panel Insulating Chambers for Leakage-Safe High Pixel Density
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Solution Overview
Problem
Existing display panels face issues with sidewall leakage channels from etched step structures, leading to increased leakage current and reduced luminous efficiency, and lower pixel density due to the distance between adjacent light-emitting devices.
Innovation Solution
A display panel design featuring insulating barrier areas surrounding each light-emitting device, formed by ion implantation, which are connected to a second electrode and integrated circuit substrate to create closed accommodating chambers, reducing lateral leakage current and allowing for higher pixel density without the need for high-precision bonding technologies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If etched step structures are used to define light-emitting devices and areas, then the devices can be formed with defined boundaries, but sidewalls of the etched structures form leakage channels that increase leakage current and reduce luminous efficiency
Solution Approach 1:
The patent extracts and removes the problematic sidewall leakage channels by filling the insulating material into the etched step structures and planarizing the surface. This eliminates the harmful sidewalls while preserving the boundary definition function, thereby resolving the contradiction between manufacturing precision and reliability.
2Manufacturing precision
If etched step structures are used to define light-emitting devices, then devices can be formed with clear boundaries, but the distance between adjacent light-emitting devices increases, reducing pixel density
Solution Approach 1:
The patent removes the excessive distance problem by filling and planarizing the etched step structures, eliminating the need for large spacing between devices. This allows adjacent light-emitting devices to be positioned closer together while maintaining clear boundary definition, thereby increasing pixel density without sacrificing manufacturing precision.
3Reliability
If insulating layers are added to eliminate leakage channels, then leakage current is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the insulating layer formation with the existing etched step structure filling process. By combining these functions into a single planarization step, the solution reduces leakage current while minimizing the increase in manufacturing process complexity.
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 effectively minimizes lateral leakage current, enhances luminous efficiency, and increases pixel density by insulating adjacent devices, while simplifying manufacturing processes and reducing costs.
Implementation Method 1
performing ion implantation on each of the insulating barrier areas from a side of the light-emitting device layer, so that at least respective parts of the light-emitting device layer in the insulating barrier areas are converted into the plurality of insulating layers
Data Source
AI summary
A display panel includes an integrated circuit substrate, a light-emitting device layer and a second electrode. The light-emitting device layer includes light-emitting devices disposed respectively in light-emitting areas and insulating layers disposed respectively in insulating barrier areas, and each insulating barrier area is disposed between two adjacent light-emitting areas. Each insulating layer has opposite ends respectively connected to the second electrode and the integrated circuit substrate and each light-emitting device is surrounded by several insulating layers, so that the several insulating layers, the second electrode and the integrated circuit substrate together form a closed accommodating chamber for accommodating the light-emitting device.