Quantum Dot Display Pixels With Compact Emitters for Defect Inspection
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Solution Overview
Problem
Existing display devices require laborious visual inspection to identify defects in the organic EL elements, which is inefficient and time-consuming.
Innovation Solution
A display device design incorporating main light-emitting elements and compact light-emitting elements, where the compact elements are smaller and used for precise inspection of non-uniformities in the light-emitting layer, allowing for easier detection of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection is used to identify defects in organic EL elements, then defect detection is possible, but the inspection process becomes laborious and time-consuming
Solution Approach 1:
The patent uses compact light-emitting elements as test samples that replicate the light-emitting layer structure of main elements. By inspecting these smaller copies, the system achieves efficient detection of film non-uniformities without requiring time-consuming visual inspection of all main elements, thus resolving the contradiction between detection capability and inspection time
Solution Approach 2:
The patent changes the size parameter of light-emitting elements by creating compact versions with smaller dimensions. These compact elements emit light that reveals non-uniformities in the light-emitting layer, enabling automated optical inspection that is both fast and accurate, thereby reducing inspection time while maintaining defect detection capability
2Reliability
If visual inspection by workers is used to check luminance of each region, then defect identification is possible, but the manufacturing process becomes complex and inefficient
Solution Approach 1:
The compact light-emitting elements serve as simplified copies for quality testing. Their smaller size and controlled structure make them ideal for automated inspection systems, allowing reliable defect identification without requiring manual visual inspection, thus maintaining reliability while improving manufacturing efficiency
Solution Approach 2:
The patent replaces the mechanical/visual inspection method (workers visually checking luminance) with an automated optical inspection system using compact light-emitting elements. This substitution eliminates manual labor from the inspection process, improving productivity while maintaining or enhancing defect identification accuracy through consistent automated measurement
3Productivity
If compact light-emitting elements are used for inspection, then non-uniformities in light-emitting layer can be detected efficiently, but additional elements increase device complexity
Solution Approach 1:
The patent segments the inspection function from the main light-emitting elements by creating separate compact test elements. These segmented compact elements are specifically designed for quality inspection purposes, allowing efficient non-uniformity detection without complicating the main element structure, thus improving productivity while managing device complexity through functional separation
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
Enables efficient and precise inspection of non-uniformities in the light-emitting layer, reducing the need for laborious visual checks and improving manufacturing efficiency.
Implementation Method 1
red light-emitting organic EL (Electro Luminescence) elements, green light-emitting organic EL elements, and blue light-emitting organic EL elements
Implementation Method 2
at least one main light-emitting element containing quantum dots in the light-emitting layer
Data Source
AI summary
A display device includes a plurality of light-emitting elements each including: a first electrode; a second electrode; and a light-emitting layer between the first electrode and the second electrode, the plurality of light-emitting elements including: at least one main light-emitting element containing quantum dots in the light-emitting layer; and at least one set of compact light-emitting elements including a plurality of compact light-emitting elements smaller than the at least one main light-emitting element.