Micro-LED Display Optical Layer Structure to Block Metal Particle Diffusion
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Solution Overview
Problem
Micro light-emitting diode display apparatuses face challenges with the diffusion of fine metal particles, which can lead to reduced reliability and lifespan due to the organic materials used, and can also damage the cathode electrode and increase its resistance.
Innovation Solution
A display panel design that includes a substrate, insulating layers, bank patterns, electrodes, light-emitting elements, and optical layers, where a first optical layer with fine metal particles surrounds the light-emitting element, and a third optical layer without fine metal particles is applied on top to prevent diffusion and ensure flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a first optical layer including fine metal particles is used to surround the light-emitting element, then light emission efficiency is improved, but fine metal particles may diffuse and damage the cathode electrode
Solution Approach 1:
A third optical layer is introduced as an intermediary barrier between the first optical layer containing fine metal particles and the cathode electrode. This third layer prevents the fine metal particles from diffusing onto and damaging the cathode electrode, while still allowing the first optical layer to maintain its light emission enhancement function.
Solution Approach 2:
The optical layers are segmented into multiple distinct layers: a first optical layer for light emission enhancement, a second optical layer, and a third optical layer for protection. This segmentation allows each layer to have specialized functions - the first layer contains fine metal particles for improving light emission, while the third layer provides protection without interfering with the light emission function.
2Illumination intensity
If fine metal particles are included in the optical layer, then light emission efficiency is improved, but the flatness of the optical layer surface is reduced
Solution Approach 1:
The optical structure is divided into multiple layers where the fine metal particles are confined to the first optical layer. The third optical layer is positioned above to provide a flat surface, effectively separating the light-enhancing function (requiring particles) from the surface flatness requirement.
3Ease of manufacture
If organic insulating material is used in the optical layer, then manufacturing ease is improved, but vulnerability to moisture increases
Solution Approach 1:
The optical layers are constructed using composite materials - organic insulating materials provide ease of manufacture and processing, while inorganic materials (such as metal oxide particles) are incorporated to provide moisture resistance and structural stability, creating a composite structure that combines the advantages of both material types.
Data Source
AI summary
A display panel and a display apparatus including the display panel are presented herein. A display panel according to one or more embodiments includes a substrate; an insulating layer on the substrate; a bank pattern on the insulating layer; a first electrode on the bank pattern; a contact electrode on the insulating layer, the contact electrode spaced apart from the bank pattern; a light-emitting element on the first electrode; a first optical layer surrounding the light-emitting element, the first optical layer comprising an organic insulating material including metal particles; a second optical layer on the contact electrode; and a third optical layer on the first optical layer.