OLED Insulating Layer Barrier for Impurity Control
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Solution Overview
Problem
Current display technologies face challenges in achieving high-resolution, high-quality, low-power, and high-contrast displays, particularly in devices like smartphones, tablets, and virtual/augmented reality devices, due to limitations in the manufacturing processes and materials used for organic light-emitting diodes (OLEDs).
Innovation Solution
The proposed solution involves a display device structure comprising multiple light-emitting elements with separate EL layers and protective layers, where an insulating layer is placed between them to reduce impurity ingress and enhance reliability, and a method for manufacturing this structure without the use of metal masks, allowing for precise control over the distance between EL layers and improved aperture ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple light-emitting elements are positioned adjacent to each other to increase pixel density, then resolution is improved, but impurity ingress between elements increases and reliability deteriorates
Solution Approach 1:
An insulating layer is introduced as an intermediary between adjacent light-emitting elements (EL layers). This insulating layer acts as a barrier that prevents impurity ingress while allowing the elements to remain closely positioned, thus maintaining high pixel density without compromising reliability.
2Reliability
If protective layers are added to cover side surfaces of EL layers to prevent impurity ingress, then reliability is improved, but device complexity increases
Solution Approach 1:
The protective function is merged into the insulating layer that is already positioned between adjacent EL layers. By combining the insulation function with the protective function in a single layer, the patent avoids adding separate protective layers, thus improving reliability without significantly increasing device complexity.
3Area of stationary object
If the distance between adjacent EL layers is reduced to increase aperture ratio, then display quality is improved, but manufacturing precision requirements increase
Solution Approach 1:
The insulating layer serves as a mediator that enables precise positioning of adjacent EL layers. By providing a defined structural element between elements, it facilitates accurate manufacturing and alignment, allowing the distance between EL layers to be reduced to increase aperture ratio while maintaining manufacturing precision.
4Manufacturing precision
If complex pixel arrangements are used to achieve high resolution, then display quality is improved, but device complexity increases
Solution Approach 1:
The patent segments the display into discrete light-emitting elements with clear boundaries defined by insulating layers. This segmentation approach simplifies the overall structure by creating modular, independent elements that can be systematically arranged, reducing device complexity while maintaining high resolution through precise positioning.
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 approach enables the production of high-resolution displays with improved reliability and contrast, reducing the need for complex pixel arrangements and achieving higher pixel densities without increasing power consumption.
Implementation Method 1
an insulating layer is placed between them to reduce impurity ingress and enhance reliability
Implementation Method 2
By applying voltage to this element, light emission can be obtained from the light-emitting organic compound
Data Source
AI summary
A highly reliable display device with high display quality is provided. The display device includes a first light-emitting element, a second light-emitting element provided to be adjacent to the first light-emitting element, a first protective layer, a second protective layer, and an insulating layer. The first light-emitting element includes a first pixel electrode, a first EL layer, and a common electrode, and the second light-emitting element includes a second pixel electrode, a second EL layer, and the common electrode. The first EL layer is provided over the first pixel electrode, and the second EL layer is provided over the second pixel electrode. The first protective layer includes a region in contact with the side surface of the first EL layer, and the second protective layer includes a region in contact with the side surface of the second EL layer. The insulating layer is provided between the first protective layer and the second protective layer. The common electrode is provided over the first EL layer, over the second EL layer, over the first protective layer, over the second protective layer, and over the insulating layer.