Multi-Layer Insulating Structure for OLED Pixel Protection
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Solution Overview
Problem
Current display devices face challenges in achieving high resolution, high contrast, and low power consumption while maintaining high display quality, particularly in manufacturing processes that require precise alignment and protection of organic electroluminescent layers.
Innovation Solution
A display device structure incorporating multiple insulating layers with specific materials (organic and inorganic) to protect the electroluminescent layers, reduce oxygen and moisture ingress, and enhance the common electrode's coverage, allowing for closer pixel spacing and higher aperture ratios without short circuits or disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulating layers are added to protect EL layers and reduce oxygen/moisture ingress, then reliability and display quality improve, but device complexity increases
Solution Approach 1:
The insulating layer is divided into multiple segments: a first insulating layer containing inorganic material, a second insulating layer containing organic material, and a third insulating layer containing inorganic material. Each layer serves specific protective functions, with the organic layer providing flexibility and adhesion while inorganic layers provide barrier properties against oxygen and moisture.
Solution Approach 2:
The patent employs a composite insulating structure combining organic and inorganic materials. The second insulating layer (organic) overlaps with EL layer side surfaces, while the first and third insulating layers (inorganic) provide additional protection. This composite approach leverages the complementary properties of different materials to achieve superior protection without excessive complexity.
2Manufacturing precision
If pixel spacing is reduced to achieve higher resolution, then display quality improves, but manufacturing precision requirements increase
Solution Approach 1:
The protective function is extended from a two-dimensional planar layer to a three-dimensional structure by having the second insulating layer overlap with the side surfaces of the EL layers. This vertical extension creates additional protective barriers that prevent short circuits even when horizontal pixel spacing is reduced, enabling higher resolution displays.
Solution Approach 2:
The insulating layers are formed and positioned to overlap with EL layer side surfaces before final pixel assembly. This preliminary protective arrangement ensures that even with reduced pixel spacing, the insulating structures are already in place to prevent short circuits and maintain manufacturing reliability.
3Use of energy by moving object
If aperture ratio is increased to improve display quality, then power consumption decreases, but protection coverage of EL layers becomes insufficient
Solution Approach 1:
By extending the insulating layers vertically to overlap with EL layer side surfaces, the patent achieves comprehensive protection without increasing the horizontal footprint. This allows the aperture ratio to be increased (improving power efficiency) while maintaining adequate protection coverage through the three-dimensional insulating structure.
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 proposed structure enables the production of high-resolution, high-contrast displays with low power consumption by ensuring reliable protection and efficient manufacturing processes, achieving aperture ratios close to 100% and resolutions exceeding 5000 ppi.
Implementation Method 1
the first insulating layer and the third insulating layer each contain an inorganic material... the second insulating layer overlaps with a side surface of the first EL layer and a side surface of the second EL layer with the first insulating layer therebetween
Implementation Method 2
the second insulating layer contains an organic material... the second insulating layer overlaps with the common electrode with the third insulating layer therebetween
Data Source
AI summary
Provided is a display device with high display quality. A first pixel, a second pixel provided adjacent to the first pixel, a first insulating layer, a second insulating layer over the first insulating layer, and a third insulating layer over the second insulating layer are included; the first pixel includes a first pixel electrode, a first EL layer over the first pixel electrode, and a common electrode over the first EL layer; the second pixel includes a second pixel electrode, a second EL layer over the second pixel electrode, and the common electrode over the second EL layer; the first insulating layer and the third insulating layer each contain an inorganic material; the second insulating layer contains an organic material; the second insulating layer overlaps with the side surface of the first EL layer and the side surface of the second EL layer with the first insulating layer therebetween; the second insulating layer overlaps with the common electrode with the third insulating layer therebetween; and the third insulating layer is in contact with the first insulating layer in a region not overlapping with the second insulating layer.