OLED Emitting Layer Overlap to Prevent Pixel Current Leakage
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Solution Overview
Problem
Existing display technologies face challenges in achieving high resolution, aperture ratio, luminance, contrast, and reliability due to issues such as current leakage and misalignment in forming light-emitting layers, which degrade display quality and efficiency.
Innovation Solution
The use of a novel structure with overlapping light-emitting layers and insulating layers, combined with a manufacturing method that includes etching and resin layer formation, to prevent current leakage and improve alignment, resulting in high-resolution, high-aperture ratio displays with increased luminance and contrast.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional light-emitting element configurations are used, then manufacturing processes are simpler, but resolution and aperture ratio cannot achieve high levels simultaneously
Solution Approach 1:
The patent transitions from planar light-emitting layers to three-dimensional stacked structures where light-emitting layers are arranged in multiple layers vertically. This dimensional change allows pixels to be densely packed in the plane (high resolution) while each pixel maintains sufficient light-emitting area through vertical stacking (high aperture ratio), resolving the contradiction between resolution and aperture ratio.
Solution Approach 2:
The patent implements a nested structure where multiple light-emitting layers are stacked within the same pixel footprint. Each light-emitting layer contains encapsulation layers and functional sub-layers nested within it. This nesting allows multiple light-emitting elements to occupy the same planar space, achieving high pixel density without sacrificing individual pixel performance.
2Manufacturing precision
If higher resolution is achieved through conventional methods, then aperture ratio decreases, but the patent achieves both high resolution and high aperture ratio
Solution Approach 1:
By stacking light-emitting layers vertically in the third dimension, the patent decouples the relationship between planar pixel density and light-emitting area. Higher resolution is achieved by reducing pixel pitch in the plane, while aperture ratio is maintained by increasing the number of light-emitting layers vertically, allowing both parameters to improve simultaneously.
Solution Approach 2:
The patent merges multiple light-emitting layers into a single pixel structure, combining their light output to maintain high luminance despite smaller individual layer areas. This merging allows the aperture ratio to be effectively increased through vertical integration rather than horizontal expansion.
3Area of stationary object
If stacked light-emitting layers are used to increase aperture ratio, then current leakage between layers occurs, but encapsulation layers prevent this
Solution Approach 1:
The patent introduces encapsulation layers as intermediary structures between adjacent light-emitting layers and between light-emitting layers and electrodes. These encapsulation layers act as barriers that prevent direct contact and current leakage while allowing the stacked structure to function, thus enabling high aperture ratio without compromising reliability.
Solution Approach 2:
The encapsulation layers are built into the structure beforehand to prevent current leakage before it can occur. By pre-establishing these protective barriers during manufacturing, the patent eliminates the risk of short circuits between stacked layers, ensuring reliability while maintaining the high-aperture-ratio stacked configuration.
4Illumination intensity
If more light-emitting layers are stacked to increase luminance, then manufacturing complexity increases, but the patent maintains reliability
Solution Approach 1:
The patent employs a universal encapsulation layer design that serves multiple functions: electrical insulation between layers, mechanical protection of light-emitting materials, and structural support for the stacked configuration. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in manufacturing complexity despite adding multiple light-emitting layers for higher luminance.
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 high-resolution displays with improved luminance, contrast, and reliability by minimizing current leakage and misalignment, allowing for pixel integration with higher accuracy and efficiency.
Implementation Method 1
a light-emitting element including a light-emitting layer
Data Source
AI summary
A high-resolution display apparatus is provided. A display apparatus having a high aperture ratio is provided. The display apparatus includes a first light-emitting element and a second light-emitting element. In the first light-emitting element, a first pixel electrode, a first light-emitting layer, and a common electrode are stacked in this order. In the second light-emitting element, a second pixel electrode, a second light-emitting layer, and the common electrode are stacked in this order. A first layer and a second layer are included in a region between the first light-emitting element and the second light-emitting element. The first layer overlaps with the second light-emitting layer and includes the same material as the first light-emitting layer. The second layer overlaps with the first light-emitting layer and includes the same material as the second light-emitting layer. An end portion of the first light-emitting layer and an end portion of the first layer are provided to face each other in the region between the first light-emitting element and the second light-emitting element. An end portion of the second light-emitting layer and an end portion of the second layer are provided to face each other in the region between the first light-emitting element and the second light-emitting element.