OLED Pixel Structure Without Metal Masks for High-Resolution Displays
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Solution Overview
Problem
Existing display technologies face challenges in achieving high resolution, high display quality, high contrast, low power consumption, and reliability, particularly in devices like smartphones, tablets, laptops, televisions, and VR/AR devices, with conventional methods struggling to integrate high-resolution organic EL elements effectively.
Innovation Solution
A display apparatus with a novel structure featuring separate formation of EL layers using sacrificial layers and resist masks, eliminating the need for metal masks, allowing for precise pixel arrangement and integration of light-emitting and light-receiving devices, and utilizing ALD methods for insulating layers to enhance reliability and resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to form EL layers with metal masks, then manufacturing process is simpler, but manufacturing precision and resolution are limited
Solution Approach 1:
The patent segments the formation process into multiple steps using sacrificial layers and resist masks instead of a single metal mask step. The EL layer is formed in multiple stages with intermediate insulating layers, allowing precise pixel arrangement while managing process complexity through systematic division of the formation process.
Solution Approach 2:
The patent applies preliminary action by forming insulating layers and sacrificial layers before forming the EL layer. These preliminary structures serve as templates and protective layers that enable precise pixel definition and prevent short circuits during subsequent processing steps.
2Manufacturing precision
If pixel size is reduced for higher resolution, then display resolution improves, but aperture ratio decreases
Solution Approach 1:
The patent applies local quality by providing insulating layers and sacrificial layers specifically at pixel boundaries and between adjacent pixels. This localized insulation allows pixels to be placed closer together (reducing pixel size for higher resolution) while preventing electrical interference, thereby maintaining higher aperture ratios despite reduced pixel dimensions.
3Reliability
If insulating layers are not properly provided between adjacent pixels, then device complexity is reduced, but reliability decreases due to short circuits
Solution Approach 1:
The patent uses insulating layers and sacrificial layers as intermediary structures between adjacent pixels. These intermediary layers serve as electrical isolators that prevent short circuits between neighboring pixels while allowing the overall device structure to remain manageable through systematic layering and processing steps.
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 solution enables high-resolution displays with improved aperture ratios, reduced pixel size, and enhanced display quality, reliability, and lower power consumption, while allowing for integration of touch and image sensing capabilities.
Implementation Method 1
utilizing ALD methods for insulating layers to enhance reliability and resolution
Implementation Method 2
a layer containing a light-emitting organic compound is provided between a pair of electrodes. By voltage application to this element, light emission can be obtained from the light-emitting organic compound
Data Source
AI summary
A display apparatus with high display quality is provided. A highly reliable display apparatus is provided. A display apparatus with low power consumption is provided. A display apparatus with a high resolution is provided. A display apparatus with high contrast is provided. The display apparatus includes a plurality of pixels over a first insulating layer. Each of the plurality of pixels includes a first conductive layer provided along an opening portion of the first insulating layer, a second insulating layer over the first conductive layer, an EL layer over the first conductive layer and the second insulating layer, and a common electrode over the EL layer. The second insulating layer is over and in contact with the first conductive layer and placed below the EL layer. The first conductive layers of adjacent pixels are separated by a third insulating layer containing an inorganic material and a fourth insulating layer containing an organic material. A side surface of the first conductive layer and a side surface of the EL layer each include a region in contact with the third insulating layer. The fourth insulating layer is over and in contact with the third insulating layer and placed below the common electrode.