OLEDoS Electrode Layout for High-Resolution HMD Manufacturing
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Solution Overview
Problem
Existing head-mounted displays (HMDs) face challenges in achieving high-resolution images due to the complexity and cost of manufacturing processes, particularly in integrating high-resolution organic light-emitting diode on silicon (OLEDoS) display devices.
Innovation Solution
A display device design that includes a substrate with specific electrode thickness variations and a single mask process for patterning connection and reflective electrodes, reducing manufacturing costs and improving light transmittance and emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single mask process is used for patterning connection and reflective electrodes, then manufacturing complexity and cost are reduced, but manufacturing precision may be compromised
Solution Approach 1:
The patent combines the patterning of connection electrodes and reflective electrodes into a single mask process. The mask layer is formed to define both electrode types simultaneously, and a single etching step patterns both electrodes through the insulating film, merging two separate manufacturing steps into one to reduce complexity and cost.
Solution Approach 2:
The patent applies local quality by using different etching conditions for different electrode regions. The etching process is controlled to etch the connection electrode pattern and reflective electrode pattern with different depths and rates, achieving precise patterning of each electrode type despite using a single mask layer.
2Illumination intensity
If the first electrode thickness is reduced in the second portion, then light transmittance and emission efficiency are improved, but electrode strength and reliability may deteriorate
Solution Approach 1:
The patent applies local quality by creating different thickness regions within the first electrode. The second portion of the first electrode has a reduced thickness compared to other portions, optimizing light transmittance in the emission area while maintaining adequate thickness in other regions to ensure structural strength and electrical connectivity.
Solution Approach 2:
The patent controls electrode thickness in the vertical dimension (z-direction) to optimize optical performance. By reducing the thickness of the first electrode in the second portion, light can transmit more efficiently through this dimension, improving emission efficiency without compromising the overall electrode structure.
3Manufacturing precision
If multiple mask processes are used for patterning electrodes, then manufacturing precision is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent merges multiple mask processes into a single mask operation. The mask layer is designed to define both connection electrodes and reflective electrodes simultaneously, and a single etching step patterns both electrode types, eliminating the need for separate mask and etch steps for each electrode type.
Solution Approach 2:
The single mask layer serves multiple functions: it defines the pattern for connection electrodes, defines the pattern for reflective electrodes, and controls the etching depth for both electrode types. This multi-functional approach to the mask process improves productivity by reducing the number of steps while maintaining the precision needed for different electrode patterns.
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 design enhances manufacturing efficiency, reduces costs, and improves light emission efficiency, enabling high-resolution images in HMDs.
Implementation Method 1
at least one light-emitting layer on a second area of a top surface of the first electrode
Data Source
AI summary
A display device, a method for manufacturing the display device, and a head mounted display are provided. The display device includes a substrate, an insulating film on the substrate, a connection electrode on the insulating film, a reflective electrode on the connection electrode, a first electrode on the reflective electrode, a first pixel defining film on a first portion of the first electrode and exposing a second portion of the first electrode, at least one light-emitting layer on a second area of a top surface of the first electrode, and a second electrode on the at least one light-emitting layer. A thickness of the second portion of the first electrode is less than a thickness of the first portion of the first electrode.