OLED Display Pixel-Area Layer Segmentation for Reliability
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Solution Overview
Problem
Organic light-emitting diode displays are prone to degradation due to oxygen and moisture penetration through cracks, and the increasing density of pixels in larger displays complicates the manufacturing process, requiring a method to enhance reliability and yield.
Innovation Solution
A display device design where the cathode electrode of a light-emitting element is connected to a power line through a reverse-tapered connection electrode, formed in a source-drain layer, and a solution process using inkjet equipment to form the cathode electrode in contact with the power line, with a simplified structure for stable power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple organic material layers are formed over the entire area of the display panel, then the display device achieves high luminance and response rate, but oxygen and moisture penetration through cracks occurs, degrading the life of the display
Solution Approach 1:
The patent segments the organic material layers into pixel-area-specific regions rather than forming them over the entire display panel area. Each pixel's organic layers are confined to its specific region, preventing continuous penetration paths for oxygen and moisture across the entire panel, thus improving reliability while maintaining luminance performance.
Solution Approach 2:
The patent extracts or removes the organic material layers from non-pixel areas and boundary regions. By taking out these layers from areas where they would create continuous penetration paths, the patent eliminates the harmful effect of oxygen and moisture diffusion while preserving the functional organic layers in pixel areas.
2Measurement precision
If the number of pixels is densely arranged to increase resolution and size, then the display device achieves higher resolution, but the manufacturing process complexity increases and yield decreases
Solution Approach 1:
The patent employs a universal electrode structure where the same electrode pattern serves multiple functions: it acts as both the pixel electrode and extends into non-pixel areas to contact power lines. This multi-functionality simplifies the manufacturing process by reducing the number of separate structures that need to be formed, thereby lowering complexity and improving yield while maintaining high resolution.
Solution Approach 2:
The patent merges the electrode structure with the power line connection function by extending the electrode into non-pixel areas to directly contact power lines. This combining of functions reduces the number of separate manufacturing steps and structural elements, simplifying the overall manufacturing process.
3Strength
If conventional connection structures are used between cathode electrode and power line, then the display device maintains structural integrity, but resistance increases and power supply stability decreases
Solution Approach 1:
The patent extends the electrode structure into the non-pixel area dimension to create a direct connection path to power lines. This dimensional extension provides an additional conduction path that reduces resistance and improves power supply stability while maintaining structural integrity through the extended electrode design.
Data Source
AI summary
The present disclosure relates to a display device and a method of manufacturing the same, the display device including: a substrate including a pixel area and a non-pixel area adjacent to the pixel area; a power line formed on the substrate; at least one insulation layer covering the power line; a connection electrode formed on the at least one insulation layer, and connected to the power line through a contact hole; an overcoat layer placed above the connection electrode in the pixel area; and a first electrode placed above the overcoat layer, wherein the connection electrode has at least an area formed in the non-pixel area, and the first electrode extends to the non-pixel area and is connected to the connection electrode.