Island-Shaped EL Layers in Display Apparatus
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Solution Overview
Problem
Current display technologies face challenges in achieving high-resolution, high-quality, and low-power consumption displays with conventional manufacturing methods, particularly in forming island-shaped light-emitting layers for color-emitting devices, which often result in reduced aperture ratio and manufacturing yield due to the use of metal masks and sacrificial layers.
Innovation Solution
A display apparatus and manufacturing method involving island-shaped EL layers formed without a metal mask, using sacrificial layers to process EL layers into separate colors, with insulating layers covering side surfaces to prevent short circuits and enhance reliability, and employing ALD for inorganic layers and photosensitive acrylic resin for organic layers to improve resolution and aperture ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal masks and sacrificial layers are used to form island-shaped light-emitting layers, then color-emitting devices can be manufactured, but aperture ratio and manufacturing yield are reduced
Solution Approach 1:
The patent removes the metal mask and sacrificial layer components from the manufacturing process. Instead of using these traditional elements to form island-shaped light-emitting layers, the invention directly forms the light-emitting layers in desired patterns through alternative manufacturing techniques, thereby eliminating the negative impacts on aperture ratio and manufacturing yield while still enabling color-emitting device production
Solution Approach 2:
The patent performs preliminary patterning of the light-emitting layers before device assembly. By pre-forming the light-emitting layers in their final island shapes without requiring subsequent removal of sacrificial layers or metal masks, the manufacturing process achieves higher precision and yield while maintaining the capability to produce color-emitting devices
2Reliability
If insulating layers are added to cover side surfaces of EL layers, then short circuits are prevented and reliability is enhanced, but device structure becomes more complex
Solution Approach 1:
The insulating layers in the patent serve multiple functions simultaneously: they provide electrical insulation to prevent short circuits between adjacent EL layers, acts as protective barriers during manufacturing processes, and contribute to the overall structural integrity of the device. This multi-functionality approach enhances reliability while minimizing the increase in device complexity
Solution Approach 2:
The patent employs thin film insulating layers that conformally coat the side surfaces of the EL layers. These thin films provide effective short circuit prevention without adding significant structural complexity or volume to the device, maintaining a compact and efficient structure while enhancing reliability
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 method enables high-resolution, high-aperture ratio displays with improved reliability and reduced manufacturing complexity, allowing for closer pixel spacing and efficient light extraction, while minimizing power consumption and manufacturing costs.
Implementation Method 1
employing ALD for inorganic layers
Implementation Method 2
photosensitive acrylic resin for organic layers
Implementation Method 3
island-shaped EL layers formed without a metal mask
Data Source
AI summary
A display apparatus having high display quality is provided. The display apparatus includes a first pixel, a second pixel, a first insulating layer, and a second insulating layer over the first insulating layer; the first pixel includes a first pixel electrode, a first EL layer covering the first pixel electrode, a third insulating layer over the first EL layer, and a common electrode over the first EL layer and the third insulating layer; the second pixel includes a second pixel electrode, a second EL layer covering the second pixel electrode, a fourth insulating layer over the second EL layer, and the common electrode over the second EL layer and the fourth insulating layer; the first insulating layer and the third insulating layer each include a first protruding portion over the first pixel electrode; the first protruding portion is positioned outward from an end portion of the second insulating layer; the first insulating layer and the fourth insulating layer each include a second protruding portion over the second pixel electrode; the second protruding portion is positioned outward from an end portion of the second insulating layer; a side surface of the first protruding portion and a side surface of the second protruding portion each have a tapered shape in a cross-sectional view of the display apparatus.