OLED Array Substrate with Corrugated Reflection Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Array substrates with microcavity structures in OLED display devices have complicated fabrication processes and high costs due to the need for multiple patterning processes and dual-tone masks to achieve anodes of different thicknesses for various pixel units.
Innovation Solution
An array substrate design with a TFT drive layer, a microcavity structure formed between a reflection layer and a transflective layer, and a color filter film disposed between the reflection layer and the OLED, where the reflection layer has a concave-convex or corrugated structure for diffuse reflection, allowing for adjustable microcavity thickness and simplified fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple patterning processes and dual-tone masks are used to form anodes of different thicknesses for various pixel units, then microcavity structures with different thicknesses can be achieved, but the fabrication process becomes complicated and cost increases
Solution Approach 1:
The invention divides the microcavity structure into two separate components: a common base layer formed by standard patterning processes, and variable thickness adjustment layers formed separately for different pixel units. This segmentation allows each layer to be optimized independently, achieving precise thickness control without requiring complex dual-tone mask processes.
Solution Approach 2:
The invention transitions from controlling microcavity thickness through complex in-plane patterning (2D approach) to controlling it through vertical layering (3D approach). By adding thickness adjustment layers in the vertical dimension, the patent achieves precise thickness differentiation for different pixel units using simple sequential deposition processes.
2Manufacturing precision
If multiple patterning processes and dual-tone masks are used to form anodes of different thicknesses, then microcavity structures can be achieved, but fabrication cost increases
Solution Approach 1:
The invention divides the microcavity structure into two separate components: a common base layer formed by standard patterning processes, and variable thickness adjustment layers formed separately for different pixel units. This segmentation allows each layer to be optimized independently, achieving precise thickness control without requiring complex dual-tone mask processes.
Solution Approach 2:
The invention transitions from controlling microcavity thickness through complex in-plane patterning (2D approach) to controlling it through vertical layering (3D approach). By adding thickness adjustment layers in the vertical dimension, the patent achieves precise thickness differentiation for different pixel units using simple sequential deposition processes.
3Loss of energy
If microcavity structures are formed to enhance light emission, then luminous efficiency improves, but the fabrication process becomes complicated
Solution Approach 1:
The invention divides the microcavity structure into two separate components: a common base layer formed by standard patterning processes, and variable thickness adjustment layers formed separately for different pixel units. This segmentation allows each layer to be optimized independently, achieving precise thickness control without requiring complex dual-tone mask processes.
Solution Approach 2:
The invention transitions from controlling microcavity thickness through complex in-plane patterning (2D approach) to controlling it through vertical layering (3D approach). By adding thickness adjustment layers in the vertical dimension, the patent achieves precise thickness differentiation for different pixel units using simple sequential deposition processes.
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 design simplifies the fabrication process, reduces costs, and enhances luminous efficiency by up to 50% through diffuse reflection and precise light emission, while maintaining high aperture ratio and reducing leakage current.
Implementation Method 1
a reflective surface of the reflection layer has a concave-convex or corrugated structure thereon for causing diffuse reflection of light
Implementation Method 2
light is continuously reflected between the two layers. Due to the resonance effect, light with specific wavelength in the light eventually emitted from the transflective layer is enhanced
Data Source
AI summary
This invention provides an array substrate, a method for fabricating the same, and an OLED display device. Each pixel unit of the array substrate comprises: a TFT drive layer; an OLED further away from the substrate than the TFT drive layer and driven by it, the OLED sequentially comprises a first electrode, a light emitting layer, a second electrode, wherein the first electrode is transparent, and the second electrode is a transflective layer, or the second electrode is transparent and has a transflective layer disposed thereon; a reflection layer disposed between the TFT drive layer and the OLED and forming a microcavity structure with the transflective layer, and a reflective surface of the reflection layer has a concave-convex or corrugated structure disposed thereon for causing diffuse reflection of light; and a color filter film disposed between the reflection layer and the OLED and located in the microcavity structure.