Display Substrate Spacer for Carrier Injection Layer Segmentation
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Solution Overview
Problem
Micro OLED displays face challenges with high image resolution due to limited accuracy of fine metal masks in forming organic functional layers, leading to electric leakage between sub-pixels and color cross-talk, which reduces color gamut and display quality.
Innovation Solution
A display substrate design with a spacer between adjacent sub-pixel areas, dividing the carrier injection layer and preventing lateral electric leakage, combined with a CMOS integrated circuit on a silicon substrate for improved accuracy and resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fine metal mask is used to form organic functional layers in micro OLED displays, then the manufacturing precision and resolution are improved, but the accuracy is limited and causes electric leakage between sub-pixels
Solution Approach 1:
The patent divides the carrier injection layer into separate portions for adjacent sub-pixels using a spacer structure. The spacer physically segments the continuous carrier injection layer into discrete segments, preventing lateral electric leakage between sub-pixels while maintaining the integrity of each sub-pixel's carrier injection function.
Solution Approach 2:
The spacer acts as an intermediary element between adjacent sub-pixels. It is positioned between the sub-pixels and the carrier injection layer, serving as a mediating structure that prevents direct lateral connection of the carrier injection layer while allowing vertical carrier injection to proceed normally.
2Ease of manufacture
If the carrier injection layer is continuous across sub-pixels, then the manufacturing process is simplified, but color cross-talk occurs and color gamut is reduced
Solution Approach 1:
The carrier injection layer is segmented into separate portions for each sub-pixel by the spacer structure. This segmentation prevents color cross-talk between adjacent sub-pixels while maintaining a relatively simple manufacturing process, as the segmentation is achieved through the spacer rather than complex patterning of the carrier injection layer itself.
Solution Approach 2:
The harmful continuous connection between carrier injection layer portions of adjacent sub-pixels is extracted or removed by the spacer. The spacer takes out the problematic lateral connection while preserving the necessary vertical carrier injection function, thereby eliminating color cross-talk.
3Measurement precision
If sub-pixels are placed closely together for high resolution, then the display resolution is improved, but electric leakage and color cross-talk increase
Solution Approach 1:
The spacer serves as an intermediary barrier between closely placed sub-pixels. It enables high display resolution by allowing sub-pixels to be positioned close together while preventing electric leakage and color cross-talk through its insulating and separating function.
Solution Approach 2:
The spacer introduces a vertical dimension solution to a lateral problem. By addressing the electric leakage issue in the vertical direction (through the spacer height) rather than solely relying on lateral spacing, the patent enables closer sub-pixel placement while maintaining reliability.
Data Source
AI summary
A display substrate and a manufacturing method thereof are provided. The display substrate includes a base substrate, as well as a first conductive layer, an organic functional layer and a second conductive layer which are on the base substrate sequentially, and the organic functional layer includes a carrier injection layer including a first carrier injection layer portion and a second carrier injection layer portion which are in a first sub-pixel area and a second sub-pixel area respectively; the display substrate further includes a spacer which separates the first carrier injection layer portion and the second carrier injection layer portion, and the carrier injection layer further includes a third carrier injection layer portion which is separated from the first carrier injection layer portion and the second carrier injection layer portion respectively.