Display Pixel Electrode Segmentation for Leakage Prevention
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Solution Overview
Problem
Current display technologies face challenges in achieving high-definition, high-aperture ratio, and high-reliability display apparatuses with efficient manufacturing processes, particularly in reducing the distance between light-emitting devices and forming precise island-shaped light-emitting layers without leakage current and manufacturing cost constraints.
Innovation Solution
A display apparatus design featuring adjacent pixels with blue light-emitting elements and color conversion layers, where the light-emitting elements are formed in an island shape with shared layers and a sacrificial layer method to reduce the distance between pixels, and an insulating layer structure using both inorganic and organic materials to prevent short circuits and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance between light-emitting devices is reduced to achieve high-definition display, then manufacturing precision and reliability become more difficult to maintain
Solution Approach 1:
The pixel electrode is divided into first and second pixel electrodes with distinct functions. The first pixel electrode serves as a lower electrode for the light-emitting device, while the second pixel electrode serves as an upper electrode. This segmentation allows independent optimization of each electrode's position and function, enabling reduced pitch between light-emitting devices while maintaining electrical isolation and preventing leakage current through proper insulating layer configuration.
Solution Approach 2:
An insulating layer is introduced as an intermediary between the first pixel electrode and the second pixel electrode. This insulating layer acts as a mediator that prevents electrical connection and leakage current between the segmented electrodes, allowing them to be positioned closer together while maintaining reliability. The insulating layer enables the reduced pitch design without compromising the electrical isolation required for device stability.
2Device complexity
If shared layers are used to reduce manufacturing cost and complexity, then manufacturing precision and reliability become more difficult to maintain
Solution Approach 1:
A sacrificial layer is formed in advance as a preliminary structure before the final pixel structures are completed. This sacrificial layer serves as a temporary template or support during manufacturing, enabling precise formation of the island-shaped light-emitting layers. The sacrificial layer is removed after serving its purpose, allowing the light-emitting layers to be positioned with high precision while using shared manufacturing steps to reduce overall complexity.
Solution Approach 2:
The sacrificial layer functions as a disposable element that is intentionally designed to be temporary and removed after use. This approach allows complex island-shaped light-emitting layers to be formed using simpler, shared manufacturing processes. The sacrificial layer is inexpensive and easily removable, enabling high-precision patterning without requiring expensive, complex equipment or multi-step processes for each individual pixel.
3Reliability
If insulating layers are added to prevent short circuits and enhance reliability, then manufacturing cost and complexity increase
Solution Approach 1:
The insulating layer is merged with existing pixel electrode structures and manufacturing processes. Rather than being a completely separate addition, the insulating layer is integrated into the electrode formation process, combining multiple functions into unified structures. This merging approach provides short circuit prevention while minimizing the increase in device complexity by sharing manufacturing steps with other pixel components.
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-resolution, high-aperture ratio display apparatuses with improved reliability and reduced manufacturing costs, achieving nearly 100% aperture ratio and high-definition displays with enhanced display quality and yield.
Implementation Method 1
a first color conversion layer over the first light-emitting element, and a second color conversion layer over the second light-emitting element; the first color conversion layer has a function of converting light emitted from the first light-emitting element into light with different wavelengths; the second color conversion layer has a function of converting light emitted from the second light-emitting element into light with different wavelengths
Data Source
AI summary
A display apparatus with high resolution or high definition is provided. The display apparatus includes a first light-emitting device, a second light-emitting device, a first insulating layer, a first color conversion layer, and a second color conversion 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; the first insulating layer covers side surfaces of the first pixel electrode, the second pixel electrode, the first light-emitting layer, and the second light-emitting layer; the first color conversion layer is positioned overlapping with the first light-emitting device; the second color conversion layer is positioned overlapping with the second light-emitting device; the first light-emitting device and the second light-emitting device each have a function of emitting blue light; and the first color conversion layer has a function of converting blue light into light with different wavelengths from the second color conversion layer.