OLED Display Apparatus with Separable Light Emitting Assembly
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Solution Overview
Problem
The low yield of organic light emitting diode (OLED) in AMOLED display screens due to defects in the light emitting layer, such as color mixing, makes it difficult to repair and results in the entire display screen becoming useless.
Innovation Solution
A display apparatus is designed with a rigid substrate having a first and second carrier plate on opposite surfaces, where a thin film transistor with a drain is formed on the first carrier plate, and a light emitting assembly with an anode electrically coupled to the drain through a via hole, allowing for easy separation and replacement of the light emitting assembly or substrate, reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the light emitting assembly is integrated with the array substrate in existing AMOLED displays, then the display structure is compact, but the entire display becomes useless when the light emitting layer has defects
Solution Approach 1:
The patent divides the display into separable modules: the array substrate with TFTs on the first carrier plate, and the light emitting assembly on the second carrier plate, connected through flexible substrates and via holes. This segmentation allows independent replacement of defective light emitting assemblies, improving manufacturing yield while maintaining display functionality.
Solution Approach 2:
The light emitting assembly is extracted as a separate replaceable module from the array substrate. By forming the light emitting assembly on the second carrier plate independently and connecting it through via holes, the patent enables removal and replacement of defective light emitting layers without damaging the array substrate, thus improving manufacturing yield.
2Ease of repair
If the light emitting assembly is separated from the array substrate, then repairability is improved, but the device structure becomes more complex
Solution Approach 1:
The display is segmented into modular components (array substrate, light emitting assembly, carrier plates, flexible substrates) that can be independently manufactured and replaced. This modular segmentation simplifies repair operations while the systematic integration through via holes and connection structures manages the overall device complexity.
Solution Approach 2:
The patent employs a nested structure where the array substrate and light emitting assembly are integrated through flexible substrates and via holes, creating a compact multi-layer configuration. This nesting approach enables easy separation for repair while maintaining a relatively simple overall structure during normal operation.
3Productivity
If defects in the light emitting layer cause entire display failure, then manufacturing yield is low, but replacement of the entire display is costly
Solution Approach 1:
By segmenting the display into replaceable light emitting assemblies and a permanent array substrate, the patent enables replacement of only the defective light emitting layer rather than the entire display. This reduces material waste and manufacturing costs while improving effective yield by salvaging functional array substrates.
Solution Approach 2:
The patent enables recovery and reuse of functional array substrates by replacing only the defective light emitting assemblies. This discards only the minimal defective component (light emitting layer) while recovering and reusing the expensive array substrate, thereby reducing manufacturing costs and material waste.
Data Source
AI summary
A display apparatus is provided, which includes a rigid substrate; a first carrier plate provided on a first surface of the rigid substrate; a first substrate provided on the first carrier plate, the first substrate including a thin film transistor with a drain; a light emitting assembly provided on a second surface of the rigid substrate distal to the first surface, the light emitting assembly including an anode and a light emitting layer provided successively along a direction distal to the rigid substrate; and a via hole provided penetrating the rigid substrate and the first carrier plate, the anode electrically coupled to the drain through the via hole. In the display apparatus of the present disclosure the light emitting assembly is separated from the array substrate such that when the light emitting assembly or the first substrate suffers from failure, it can be replaced easily.