Organic EL Layer Patterning Without Shadow Masks
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Solution Overview
Problem
Current display devices face challenges in achieving high resolution, low power consumption, high contrast, and reliable manufacturing processes, particularly in forming high-resolution organic electroluminescent (EL) layers without the use of shadow masks, which can lead to defects and reduced aperture ratios.
Innovation Solution
A display device structure featuring adjacent pixels with insulating layers and EL layers, where the EL layers are formed separately without a shadow mask, allowing for precise patterning and reduced distance between pixels, enhancing resolution and aperture ratio while minimizing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shadow masks are used to form high-resolution EL layers, then manufacturing precision can be improved, but device complexity increases and defects occur
Solution Approach 1:
The patent removes the shadow mask component from the manufacturing process entirely. EL layers are formed by directly depositing organic materials onto pixel electrodes through vacuum deposition or other deposition methods, eliminating the need for shadow masks and their associated alignment mechanisms, thereby reducing device complexity while maintaining patterning precision.
Solution Approach 2:
The mechanical shadow mask system is replaced with a direct deposition process. Instead of using a physical mask to define patterns, the patent uses controlled material deposition to form EL layers that self-align with pixel electrodes, substituting a mechanical masking system with a more precise deposition-based patterning approach.
2Manufacturing precision
If shadow masks are used for EL layer formation, then manufacturing precision can be improved, but productivity decreases due to defects
Solution Approach 1:
By removing the shadow mask step entirely, the patent eliminates defects associated with mask alignment, dust contamination, and mask damage. This streamlined process allows continuous deposition without mask changes or realignment, significantly improving manufacturing throughput and productivity while maintaining high patterning precision.
3Area of moving object
If distance between pixels is reduced for higher resolution, then display quality improves, but manufacturing precision requirements increase
Solution Approach 1:
The direct deposition method replaces mechanical shadow mask alignment, enabling precise control of EL layer dimensions at sub-pixel scales. This allows pixels to be placed closer together with accurate material deposition, achieving higher pixel density without proportionally increasing manufacturing difficulty.
4Area of moving object
If aperture ratio is increased for better display quality, then display quality improves, but device complexity increases with conventional methods
Solution Approach 1:
By eliminating the shadow mask and its support structure, the patent increases the aperture ratio as the light-emitting area occupies more of the pixel space. The simplified structure without masks allows EL layers to extend closer to pixel boundaries, increasing the effective light-emitting area while reducing structural complexity.
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
The solution enables the production of high-resolution display devices with improved aperture ratios and reduced defects, achieving both high display quality and low power consumption.
Implementation Method 1
the basic structure of an organic EL element (an organic electroluminescent element) is a structure in which a layer containing a light-emitting organic compound is provided between a pair of electrodes. By voltage application between a pair of electrodes, light emission can be obtained from the light-emitting organic compound.
Data Source
AI summary
A display device with high display quality is provided. A highly reliable display device is provided. A display device with low power consumption is provided. A display device that can easily achieve a higher resolution is provided. A display device with both high display quality and a high resolution is provided. A display device with high contrast is provided. The display device includes a first pixel, a second pixel arranged to be adjacent to the first pixel, and a first insulating layer; the first pixel includes a first pixel electrode, a first EL layer over the first pixel electrode, and a common electrode over the first EL layer; the second pixel includes a second pixel electrode, a second EL layer over the second pixel electrode, and the common electrode over the second EL layer; a side surface of the first EL layer and a side surface of the second EL layer each include a region in contact with the first insulating layer; a side surface of the first pixel electrode is covered with the first EL layer; and a side surface of the second pixel electrode is covered with the second EL layer.