OLED Display Panel Beam Diffusion Layer for Power and Burn-in Reduction
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Solution Overview
Problem
Large-sized OLED displays face challenges in mass production due to high evaporation costs, low yield, and increased power consumption, which results in heat dissipation issues and high burn-in rates.
Innovation Solution
A display panel design featuring a base substrate with a light-emitting layer and a beam diffusion layer that expands the light-emergent beam, reducing the number of pixel units required, decreasing power consumption, and improving heat dissipation, while also reducing the precision needed for the mask.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the number of pixel units is increased to achieve larger display size, then the display area is improved, but the power consumption increases and heat dissipation becomes difficult
Solution Approach 1:
The invention divides each pixel unit into multiple sub-pixel regions (first light-emitting region, second light-emitting region, third light-emitting region) with different emitting angles. This segmentation allows different regions to emit light in different directions, improving light utilization efficiency and reducing the total number of pixel units needed for large displays, thereby lowering power consumption.
Solution Approach 2:
Different sub-regions within each pixel are assigned different light-emitting characteristics (different emitting angles). The first light-emitting region emits at a first angle, the second at a second angle, and the third at a third angle. This local differentiation optimizes light distribution across the display, improving efficiency and reducing overall power requirements.
2Area of stationary object
If the number of pixel units is increased to achieve larger display size, then the display area is improved, but heat dissipation becomes difficult and burn-in rate increases
Solution Approach 1:
By segmenting each pixel into multiple sub-regions with different emitting angles, the invention improves light extraction efficiency. This reduces the energy converted to heat and decreases the total number of pixels needed for large displays, thereby reducing overall heat generation and improving heat dissipation.
Solution Approach 2:
The invention converts what would normally be wasted light (emitted at various angles) into useful output by directing different sub-regions to emit at optimized angles. This improves overall light utilization efficiency, reducing the energy waste that would otherwise become heat, thus mitigating the heat dissipation problem in large displays.
3Manufacturing precision
If the precision of the mask is increased to improve manufacturing accuracy, then the manufacturing precision is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The invention segments each pixel into multiple sub-regions that can be defined by simpler mask patterns. By using multiple light-emitting regions with different emitting angles rather than requiring extremely precise single-pixel definitions, the mask complexity is reduced while still achieving the desired display quality.
Solution Approach 2:
Instead of using high-precision masks to define each pixel boundary exactly, the invention inverts the approach by using lower-precision masks to define broader regions, then using the emitting angle differentiation to achieve precise light control. This trades mask precision for optical control, simplifying the manufacturing process.
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
The solution allows for easier manufacturing of large-sized OLED displays by reducing the number of pixel units, decreasing power consumption, and minimizing burn-in rates, while maintaining effective light emission and display quality.
Implementation Method 1
the beam diffusion element is used to expand a light-emergent beam of the corresponding pixel unit
Data Source
AI summary
A display panel and manufacturing method thereof and a display device are provided. The display panel includes: a base substrate, a light-emitting layer located on the base substrate, and a beam diffusion layer located on the side of a light-emergent surface of the light-emitting layer. The light-emitting layer includes a plurality of pixel units arranged in an array; and the beam diffusion layer includes a beam diffusion element corresponding to at least one of the pixel units, which is used to expand a light-emergent beam of the corresponding pixel unit. The beam diffusion element may expand the light-emergent beam of the corresponding pixel unit, which increases the area of the light-emergent surface of the pixel unit. Thus, the number of pixel units provided in a large-sized display panel may be reduced, the power consumption thereof may be decreased, and the occurrence of burn-in inside the display panel may be avoided.