OLED Pixel Isolation Structure for High-Resolution Display Aperture
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Solution Overview
Problem
Existing display technologies face challenges in achieving high resolution, high display quality, high contrast, and reliable manufacturing with conventional methods, particularly due to limitations in pixel arrangement and layer formation using metal masks.
Innovation Solution
A display device with a novel structure featuring separate formation of EL layers between light-emitting elements using a sacrificial film etching method, combined with an insulating layer to reduce overlap and increase aperture ratio, allowing for high-resolution and high-contrast displays without the need for complex pixel arrangements like PenTile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional metal mask methods are used for pixel formation, then manufacturing process is simple, but resolution and aperture ratio are limited
Solution Approach 1:
The pixel electrodes are divided into independent island-shaped regions separated by insulating layers. This segmentation allows each pixel to be formed independently through etching, enabling high-resolution displays without requiring complex overlapping pixel arrangements like PenTile. The insulating layers create clear boundaries between adjacent pixels, maintaining manufacturing simplicity while achieving superior resolution.
Solution Approach 2:
The patent introduces insulating layers that extend in the vertical dimension between pixel electrodes. This adds a new dimensional approach to pixel isolation, allowing apertures to be defined not just by horizontal spacing but also by vertical insulation layers. This enables higher aperture ratios and resolutions without increasing lateral complexity.
2Manufacturing precision
If insulating layers are added between pixel electrodes, then aperture ratio and resolution improve, but manufacturing complexity increases
Solution Approach 1:
The insulating layers are merged with the existing pixel electrode formation process. The same etching steps that define pixel boundaries also create the insulating layer structures. By combining multiple functions into unified process steps, the patent improves aperture ratio and resolution without proportionally increasing manufacturing complexity.
Solution Approach 2:
The insulating layers serve multiple functions simultaneously: they electrically isolate adjacent pixels, define aperture boundaries, provide mechanical support, and facilitate subsequent EL layer formation. This multi-functionality reduces the need for additional specialized process steps, maintaining ease of manufacture while achieving superior display characteristics.
3Manufacturing precision
If pixel density is increased for higher resolution, then display quality improves, but manufacturing yield decreases
Solution Approach 1:
The insulating layers provide localized quality control at each pixel boundary. By ensuring proper insulation and electrical isolation at each individual pixel interface, the patent maintains consistent performance even at high pixel densities. This local quality assurance prevents defect propagation and maintains high manufacturing yield across the entire display panel.
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 method enables high-resolution displays with improved aperture ratios, high display quality, and reliable manufacturing yield, achieving resolutions up to 5000 ppi with effective light-emitting areas exceeding 70%.
Implementation Method 1
An insulating layer is included between the first pixel electrode and the second pixel electrode
Implementation Method 2
By voltage application to this element, light emission can be obtained from the light-emitting organic compound
Data Source
AI summary
A high-resolution display device is provided. A display device with both high display quality and high resolution is provided. The display device includes a first light-emitting element and a second light-emitting element. The first light-emitting element includes a first pixel electrode, a first EL layer, and a common electrode. The second light-emitting element includes a second pixel electrode, a second EL layer, and the common electrode. An insulating layer is included between the first pixel electrode and the second pixel electrode. The insulating layer includes a first region overlapping with the first EL layer, a second region overlapping with the second EL layer, and a third region positioned between the first region and the second region. A side surface of the first EL layer and a side surface of the second EL layer are positioned over the insulating layer and are provided to face each other. The common electrode is provided along the side surface of the first EL layer, the side surface of the second EL layer, and a top surface of the insulating layer. A width of the insulating layer is greater than or equal to 2 times and less than or equal to 4 times that of a distance between the first pixel electrode and the second pixel electrode.