Light-Emitting Element with Refractive Index Gradient Partition
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Solution Overview
Problem
The challenge in improving display quality, reducing power consumption, and increasing resolution in organic EL displays is hindered by the limitations of metal masks in forming light-emitting layers, including size accuracy issues and heat-induced deformation, which also restricts the reduction of partition area and enhancement of pixel aperture ratio.
Innovation Solution
A light-emitting element with a specific structure featuring an anode, an EL layer, a cathode, a first layer adjacent to the side surface of the EL layer, and a first portion with a refractive index lower than the first layer, where the angle between the bottom surface and side surface of the EL layer is greater than 90°, allowing for a top-emission display apparatus with improved flexibility and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal mask is used to form the light-emitting layer, then the formation process is simplified, but the size accuracy deteriorates and heat-induced deformation occurs
Solution Approach 1:
The patent replaces the mechanical metal mask system with a photolithography-based resist mask system. This substitution eliminates the physical constraints and thermal deformation issues of metal masks while maintaining the patterning function, thereby improving size accuracy without sacrificing manufacturing ease
Solution Approach 2:
The patent changes the material parameter from metal to photoresist, which fundamentally alters the thermal and mechanical properties. The photoresist mask can withstand the deposition process without thermal deformation and achieves higher precision through photolithographic patterning, resolving the contradiction between ease of manufacture and manufacturing precision
2Reliability
If a larger partition is provided between pixels, then display quality improves and power consumption reduces, but the pixel aperture ratio deteriorates and resolution increases
Solution Approach 1:
The patent applies different refractive indices to different regions: the partition region has a lower refractive index than the light-emitting layer. This local differentiation allows the partition to effectively guide and confine light within the pixel area, improving display quality and reducing power consumption while minimizing the required partition width, thus preserving pixel aperture ratio
Solution Approach 2:
The patent changes the refractive index parameter of the partition region to be lower than that of the light-emitting layer. This parameter change enables effective light confinement with smaller partition dimensions, resolving the contradiction between improving display quality/reducing power consumption and maintaining high pixel aperture ratio
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 enhances display quality, reduces power consumption, and increases productivity by enabling a lightweight, high-resolution display with improved pixel aperture ratio and flexibility in pixel arrangement, overcoming the limitations of traditional metal mask methods.
Implementation Method 1
a first portion adjacent to the side surface of the EL layer with the first layer therebetween, in which an angle θ between a bottom surface and the side surface of the EL layer is larger than 90°, and a refractive index of the first portion is lower than a refractive index of the first layer
Data Source
AI summary
Provided is a novel light-emitting element. The light-emitting element includes an anode, an EL layer over the anode, and a cathode over the EL layer; a first layer is adjacent to a side surface of the EL layer, and a first portion is adjacent to the side surface of the first layer. The EL layer and the first portion are adjacent to each other with the first layer therebetween. A refractive index of the first portion is lower than a refractive index of the first layer. An angle θ between a bottom surface and the side surface of the EL layer is larger than 90°.