OLED Planarization Layer Structure to Prevent Contrast Loss and Dark Spots

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Solution Overview

Problem

Organic light-emitting diode (OLED) displays suffer from contrast degradation due to external light intensity and can develop dark spots from residues during the formation of a colored pixel defining layer.

Innovation Solution

Incorporating a substrate with a thin film transistor, a first transparent planarization layer, and a colored planarization layer that includes a second contact hole for electrical connection, using transparent and colored pigments or carbon black to enhance reliability and reduce defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a colored pixel defining layer is formed to prevent contrast degradation, then contrast is improved, but dark spots generate due to process residues

Engineering Contradiction:
ImprovecontrastVSAvoiddefects
Core Design Contradiction:
Illumination intensityVSReliability

Solution Approach 1:

The pixel defining layer is divided into two separate layers: a first transparent planarization layer and a second colored planarization layer. This segmentation allows each layer to perform its specific function independently - the first layer provides planarization and electrical connection without residues, while the second layer provides the coloring function to prevent contrast degradation without causing dark spots.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The harmful residues are extracted and eliminated by separating the coloring function from the planarization function. The first transparent planarization layer is formed without the colored material that causes residues, thus removing the source of dark spots while maintaining the necessary planarization and electrical connection functions.

Inventive Principle:
Principle #2Taking out (Extraction)

2Illumination intensity

If a colored pixel defining layer is formed to prevent contrast degradation, then contrast is improved, but the process complexity increases

Engineering Contradiction:
ImprovecontrastVSAvoidprocess complexity
Core Design Contradiction:
Illumination intensityVSDevice complexity

Solution Approach 1:

The first transparent planarization layer and the second colored planarization layer are merged into an integrated structure where the first layer serves as both a planarization layer and a base for the second layer. This merging reduces process complexity by combining multiple functions into a unified layered structure rather than treating them as separate independent components.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The first transparent planarization layer performs multiple functions: it provides planarization for the underlying structure, serves as an insulating layer, provides electrical connection through contact holes, and acts as a base layer for the second colored planarization layer. This multi-functionality reduces the need for additional separate layers and processes.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS12439777B2Display apparatus and method of manufacturing the same
Publication Date: 2025.10.07 SAMSUNG DISPLAY CO LTD
  • US12439777B2 patent drawing
  • US12439777B2 patent drawing
  • US12439777B2 patent drawing

AI summary

A display apparatus having improved reliability includes: a substrate; a thin film transistor on the substrate; a pixel electrode electrically connected to the thin film transistor; a first transparent planarization layer between the thin film transistor and the pixel electrode, the first transparent planarization layer including a first contact hole for electrically connecting the thin film transistor to the pixel electrode and including a transparent material; and a colored planarization layer on the first transparent planarization layer, the colored planarization layer including a second contact hole for electrically connecting the thin film transistor to the pixel electrode and including a colored pigment or carbon black.