Display Apparatus Sidewall Structure for High-Resolution Organic EL
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of high-definition display apparatuses with organic EL devices faces challenges due to inaccuracies in forming island-shaped light-emitting layers, leading to deviations in shape and position, reduced aperture ratio, and increased manufacturing costs, particularly with the use of metal masks which require frequent cleaning and multiple equipment lines.
Innovation Solution
A display apparatus structure comprising multiple light-emitting devices with insulating layers and sidewalls to cover side surfaces, allowing for precise formation of island-shaped light-emitting layers without a metal mask, enabling high-definition and high-aperture ratio displays with reduced manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a vacuum evaporation method using a metal mask is used to form island-shaped light-emitting layers, then the light-emitting layers can be formed separately for different colors, but the position and shape of the layers deviate from the designed pattern due to low accuracy of metal mask positioning, metal mask warp, and vapor scattering
Solution Approach 1:
The patent removes the metal mask from the vacuum evaporation process entirely. Instead of using a metal mask to define the pattern, the invention uses a substrate with pre-formed patterns or direct deposition methods that eliminate the metal mask component, thereby removing the sources of positioning error and warp deformation associated with metal masks
Solution Approach 2:
The patent replaces the mechanical metal mask positioning system with a different approach - likely using photolithography patterns, direct write methods, or substrate-based pattern definition. This substitution eliminates mechanical positioning errors and mask warp issues while maintaining the ability to form separate colored light-emitting layers
2Quantity of substance
If a vacuum evaporation method using a metal mask is used, then light-emitting layers can be deposited, but the outline of the layer blurs during vapor deposition causing the thickness of the end portion to be small and varying from area to area
Solution Approach 1:
By removing the metal mask from the process, the invention eliminates the vapor scattering and mask edge effects that cause outline blurring and thickness variation. The light-emitting layers can be deposited directly onto defined patterns without the harmful edge effects of metal mask vapor deposition
3Productivity
If a vacuum evaporation method using a metal mask is used, then light-emitting layers can be formed, but the metal mask needs to be cleaned on a regular basis requiring at least two equipment lines for continuous production
Solution Approach 1:
The invention removes the metal mask from the vacuum evaporation system entirely, eliminating the need for mask cleaning and replacement. This single removal resolves the requirement for multiple equipment lines and reduces maintenance complexity while maintaining continuous production capability
Solution Approach 2:
By eliminating the metal mask component, the system becomes self-sufficient without requiring external mask cleaning services or mask replacement operations. The manufacturing process can continue uninterrupted without stopping for mask maintenance activities
4Manufacturing precision
If a vacuum evaporation method using a metal mask is used, then light-emitting layers can be deposited, but the manufacturing yield is reduced due to low dimensional accuracy and deformation from heat for large size, high resolution displays
Solution Approach 1:
The invention removes the metal mask that causes dimensional inaccuracy and heat deformation. By using alternative deposition methods without metal masks, the patent achieves better dimensional accuracy and reduces manufacturing defects, thereby improving yield for large-size, high-resolution displays
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-definition, high-resolution display apparatuses with improved yield and reliability by eliminating the need for frequent equipment maintenance and reducing the complexity of manufacturing processes, achieving precise layer formation and increased aperture ratios.
Implementation Method 1
Each of an end portion of the first pixel electrode and an end portion of the second pixel electrode is covered with the insulating layer. The first sidewall is positioned over the insulating layer and covers a side surface of the first light-emitting layer.
Implementation Method 2
Light-emitting devices (also referred to as EL devices or EL elements) utilizing electroluminescence (hereinafter referred to as EL) have features such as ease of reduction in thickness and weight, high-speed response to input signals, and driving with a constant DC voltage power source
Data Source
AI summary
A high-definition and high-resolution display apparatus is provided. The display apparatus includes a first light-emitting device, a second light-emitting device, an insulating layer, and a first sidewall. 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. Each of an end portion of the first pixel electrode and an end portion of the second pixel electrode is covered with the insulating layer. The first sidewall is positioned over the insulating layer and covers a side surface of the first light-emitting layer.