Display Device Separation Layer Void Structure
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Solution Overview
Problem
Existing display devices face challenges in achieving improved reliability due to issues with the manufacturing process and the structural integrity of the display components.
Innovation Solution
A display device is designed with a specific structure that includes a first electrode on a substrate, a pixel defining layer, a separation layer with voids and openings, a light emitting unit separated by the openings, and a second electrode covering the openings. This structure is manufactured through a process involving the formation of electrodes, pixel defining layers, metal layers, and separation layers, with etching steps to create voids and openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separation layer is introduced to isolate light emitting units, then reliability is improved, but device complexity increases
Solution Approach 1:
The separation layer is divided into multiple regions: a first separation layer extending from the pixel defining layer to the metal layer, and a second separation layer extending from the metal layer to the pixel defining layer. This segmentation allows the separation function to be distributed across different structural zones, improving reliability through enhanced isolation while managing complexity through systematic design
Solution Approach 2:
The separation layer structure is nested within the existing pixel electrode and pixel defining layer framework. The first and second separation layers are positioned between the pixel defining layer and the metal layer, effectively nesting the separation function within the existing device architecture rather than adding entirely new external components
2Manufacturing precision
If etching is used to create voids and openings in the separation layer, then manufacturing precision is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The separation layer is formed with predetermined patterns of first openings and second openings before final assembly. The first openings expose portions of the pixel defining layer, and the second openings expose portions of the metal layer, allowing subsequent light emitting unit formation to proceed with high precision based on these pre-established reference structures
Solution Approach 2:
The etching process uses the separation layer as an intermediary structure to define precise locations for light emitting unit formation. The voids and openings in the separation layer serve as intermediate guides that enable accurate positioning without requiring direct etching of underlying sensitive layers
Data Source
AI summary
A display device includes: a first electrode on a substrate; a pixel defining layer on the first electrode; a separation layer on the pixel defining layer and having a void and an opening partially exposing the void; a light emitting unit on the first electrode and the separation layer, the light emitting unit being separated at the opening in the separation layer; and a second electrode on the light emitting unit and covering the opening in the separation layer.