Light Blocking Layer Layout for Display Misalignment Tolerance
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Solution Overview
Problem
Misalignment during the coupling of upper and lower structures in display devices leads to defects, particularly affecting sub-pixel areas with different light emission colors, which is exacerbated by increasing resolution requirements.
Innovation Solution
The display device incorporates a pixel defining layer on the lower substrate with specific openings and a light blocking layer on the upper substrate, where the openings are symmetrically aligned and sized to maintain consistent light emission despite misalignment, using symmetrical exposure patterns to ensure uniform light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the resolution is increased to improve display quality, then the display quality is improved, but the misalignment defect rate increases
Solution Approach 1:
The patent applies asymmetry by designing the opening in the light blocking layer to be asymmetrically positioned relative to the pixel defining layer opening. Specifically, the opening in the light blocking layer is positioned closer to one side of the pixel defining layer opening, creating an asymmetric configuration that compensates for potential misalignments during assembly. This asymmetric design ensures that even if misalignment occurs, the light emission characteristics remain relatively uniform across the sub-pixel area.
Solution Approach 2:
The patent applies local quality by making the opening in the light blocking layer have different dimensions and positions at different locations within the sub-pixel area. The opening is designed with specific width and position ratios relative to the pixel defining layer opening, creating localized variations in light transmission characteristics. This local quality differentiation helps compensate for misalignment effects and maintains overall display uniformity.
2Reliability
If the opening in the light blocking layer is made larger to compensate for misalignment, then the misalignment tolerance is improved, but the light emission uniformity deteriorates
Solution Approach 1:
The patent applies parameter changes by carefully controlling the dimensional parameters of the opening in the light blocking layer. Specifically, the opening is designed with a width that is a certain ratio of the pixel defining layer opening width, and positioned at a specific distance from one side. These parameter optimizations allow the opening to provide misalignment compensation while maintaining light emission uniformity. The parameters are tuned to achieve the right balance between tolerance and uniformity.
Solution Approach 2:
The patent applies local quality by creating non-uniform light transmission characteristics within the sub-pixel area. The opening in the light blocking layer is positioned and dimensioned to create different light transmission zones, which compensates for misalignment effects. This local quality differentiation ensures that even with larger opening dimensions, the overall light emission remains uniform across the sub-pixel.
Data Source
AI summary
A display device includes a lower substrate, a pixel defining layer, a light emitting layer, an upper substrate, and a light blocking layer. The pixel defining layer is disposed on the lower substrate and includes a first opening and a second opening spaced apart from the first opening in a first direction. The light emitting layer is disposed in each of the first opening and the second opening. The upper substrate is disposed on the light emitting layer. The light blocking layer is disposed on the upper substrate and includes a third opening partially exposing the first opening and a fourth opening partially exposing the second opening. A first shape in which the first opening is exposed by the third opening and a second shape in which the second opening is exposed by the fourth opening are symmetrical to each other about a line of symmetry in a plan view.