Dummy Pixel Electrode Opening Size for Display Yield
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Solution Overview
Problem
The existing organic EL display devices face a manufacturing yield deterioration due to the need for the same high accuracy in manufacturing dummy pixels as effective display pixels, leading to inefficiencies.
Innovation Solution
The display device incorporates a dummy display region with subpixels having a smaller opening and light-emitting layer, allowing for reduced manufacturing complexity while maintaining effective light emission, and includes a luminance sensor region to detect and compensate for degradation, thereby preventing yield deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dummy pixels are provided with the same structure as effective display pixels, then accurate light emission luminance measurement can be achieved, but manufacturing yield deteriorates due to the need for same manufacturing accuracy
Solution Approach 1:
The patent applies local quality by making the opening of the pixel electrode in the dummy pixel region different from that in the display region. Specifically, the dummy pixel has a smaller opening area than the effective display pixel, allowing relaxed manufacturing tolerances in the dummy region while maintaining measurement functionality. This localized structural differentiation resolves the contradiction by enabling accurate luminance measurement without requiring the same high manufacturing precision in dummy pixels as in display pixels.
2Reliability
If dummy pixels have the same structure as display pixels, then they can function as measurement devices, but device complexity increases and manufacturing efficiency decreases
Solution Approach 1:
The patent simplifies the dummy pixel structure by reducing the opening area of the pixel electrode in the dummy region compared to the display region. This localized structural simplification maintains the essential measurement functionality while reducing overall device complexity and manufacturing burden. The dummy pixel retains sufficient light emission capability for luminance measurement without requiring the full structural complexity of display pixels.
Solution Approach 2:
The patent treats dummy pixels as sacrificial measurement devices that do not need to maintain long-term durability or full display functionality. By providing a simplified structure with smaller opening area, the dummy pixels can be manufactured more easily and serve their measurement purpose without requiring the same level of structural investment as display pixels, effectively applying the principle of using simpler, less expensive structures for auxiliary functions.
3Ease of manufacture
If dummy pixels are provided with standard structure, then manufacturing process is standardized, but manufacturing yield deteriorates due to high accuracy requirements
Solution Approach 1:
The patent resolves the contradiction between manufacturing standardization and yield by applying local quality differentiation. The dummy pixel region uses a simplified structure with smaller opening area compared to the display region, allowing the manufacturing process to use standardized steps while imposing relaxed accuracy requirements specifically on the dummy pixel structures. This localized structural simplification enables high manufacturing yield without compromising the measurement functionality of dummy pixels.
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 configuration enables the formation of functional dummy pixels that enhance manufacturing efficiency and display quality by allowing for the use of the dummy region to contribute to information display, thus preventing yield drops and improving overall display performance.
Implementation Method 1
an organic EL display device, which uses organic electroluminescence (EL) elements (light-emitting elements)
Implementation Method 2
a luminance sensor region configured to detect a light emission luminance of the dummy display region
Data Source
AI summary
An opening, which is provided on the inner side of a first pixel electrode, which is a first electrode formed in a display region, is larger than an opening, which is provided on the inner side of a second pixel electrode, which is the first electrode formed in a dummy display region. Further, a light-emitting layer (a first light-emitting layer) formed in the display region has the same shape and the same size as a light-emitting layer (a second light-emitting layer) formed in the dummy display region.