Island-Shaped EL Layers for High-Resolution Displays
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Solution Overview
Problem
Current display apparatuses face challenges in achieving high resolution, high definition, and high reliability, particularly in manufacturing processes that require precise control over light-emitting devices to prevent leakage current and crosstalk between subpixels, which affects display quality and aperture ratio.
Innovation Solution
The display apparatus incorporates island-shaped EL layers formed without a shadow mask, utilizing the step between adjacent pixel electrodes for self-aligned local thinning, and employs sidewall insulating layers and a common electrode structure to prevent short circuits and disconnection, allowing for high-resolution and high-aperture ratio displays with improved manufacturing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shadow mask method is used to form EL layers, then manufacturing precision can be improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the shadow mask component from the manufacturing process entirely. EL layers are formed by direct deposition onto pixel electrodes without requiring a shadow mask, thereby simplifying the manufacturing process while maintaining the ability to form precise EL layer patterns through controlled deposition conditions
Solution Approach 2:
The pixel electrode structure itself serves as the alignment reference for EL layer formation. The step structure of adjacent pixel electrodes automatically defines the deposition pattern, eliminating the need for external shadow mask alignment and enabling self-aligned EL layer formation
2Illumination intensity
If aperture ratio is increased to improve display quality, then display quality is improved, but leakage current and crosstalk between subpixels increase
Solution Approach 1:
The patent segments the EL layer into isolated regions corresponding to individual subpixels. By forming separate EL layers for each subpixel with proper isolation, the patent prevents electrical crosstalk between adjacent subpixels while maintaining high aperture ratios, as each EL layer is electrically independent
Solution Approach 2:
The patent applies different properties to different regions: EL layers are formed only in regions corresponding to individual pixel electrodes, with insulating materials placed in intermediate regions. This local differentiation ensures that each subpixel operates independently without leakage current to adjacent subpixels, while maximizing the light-emitting area
3Reliability
If insulation between pixel electrodes is improved to prevent short circuits, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies insulating materials to the side surfaces of pixel electrodes before EL layer deposition. This preliminary insulation step ensures that even with variations in deposition conditions, short circuits between adjacent pixel electrodes are prevented, as the insulating layers are already in place to provide electrical isolation
Solution Approach 2:
The patent extends insulation from the traditional planar interface between pixel electrodes to the vertical side surfaces of pixel electrodes. By coating the side surfaces with insulating materials, the patent creates three-dimensional electrical isolation that prevents short circuits through a broader spatial range, reducing sensitivity to manufacturing variations
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-resolution display apparatuses with high aperture ratios and reliability, reducing leakage current and crosstalk, and enhancing display quality and manufacturing efficiency.
Implementation Method 1
Light-emitting devices (also referred to as EL devices or EL elements) utilizing electroluminescence (hereinafter referred to as EL)
Implementation Method 2
The first coloring layer and the second coloring layer have functions of transmitting light of different colors
Data Source
AI summary
A high-resolution display apparatus is provided. The display apparatus includes a first light-emitting device, a second light-emitting device, a first sidewall insulating layer, a second sidewall insulating layer, an insulating layer, a first coloring layer, and a second coloring layer. The first light-emitting device includes a first pixel electrode, a first EL layer, and a common electrode. The second light-emitting device includes a second pixel electrode, a second EL layer, and the common electrode. The first EL layer and the second EL layer emit white light. The first sidewall insulating layer is in contact with the side surface of the first pixel electrode. The second sidewall insulating layer is in contact with the side surface of the second pixel electrode. The insulating layer covers the side surface and part of the top surface of the first EL layer and the side surface and part of the top surface of the second EL layer. The first coloring layer overlaps with the first light-emitting device. The second coloring layer overlaps with the second light-emitting device. The first coloring layer and the second coloring layer have functions of transmitting light of different colors.