Pixel Insulating Layer Openings to Reduce Display Short Circuits
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Solution Overview
Problem
Existing display devices face issues with luminous efficiency and short circuit defects due to foreign material and short circuit defects.
Innovation Solution
The display device incorporates a design with a first and second electrode, light-emitting elements between them, and insulating layers with specific openings, including a bank surrounding emission and non-emission areas to minimize defects and improve efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If light-emitting elements are arranged in a continuous array across the pixel area, then the luminous efficiency is improved, but short circuit defects and foreign material defects increase
Solution Approach 1:
The pixel area is divided into a first area containing effective light-emitting elements and a second area containing ineffective light-emitting elements. This segmentation allows the device to maintain high luminous efficiency from the effective elements while isolating potential defect sources in the second area, thereby resolving the contradiction between maximizing light output and minimizing short circuit defects.
Solution Approach 2:
Ineffective light-emitting elements are extracted and concentrated into a separate second area, distinct from the first area containing effective elements. This extraction removes potential defect sources from the active light-emitting region, reducing the risk of short circuit defects while preserving the luminous efficiency of the effective elements.
2Device complexity
If insulating layers are made thinner to reduce manufacturing complexity, then the device complexity is reduced, but short circuit defects increase
Solution Approach 1:
The solution introduces a third spatial dimension by stacking multiple insulating layers (first insulating layer and second insulating layer) vertically. This multi-layer insulation structure provides enhanced electrical isolation between adjacent light-emitting elements without increasing lateral complexity, thereby preventing short circuit defects while maintaining manageable device complexity.
3Manufacturing precision
If the opening width in the insulating layer is reduced to improve manufacturing precision, then the manufacturing precision is improved, but luminous efficiency decreases
Solution Approach 1:
The opening structure is segmented into two distinct layers: a first opening in the first insulating layer and a second opening in the second insulating layer. This segmentation allows each opening to be optimized independently - the first opening can be wider to maintain luminous efficiency, while the second opening can be narrower to achieve precise manufacturing control and proper alignment, thereby resolving the contradiction between manufacturing precision and luminous efficiency.
Data Source
AI summary
A display device including a plurality of pixels, each of the pixels including a first area and a second area and including: a first electrode and a second electrode in the first area; a plurality of light-emitting elements located between the first electrode and the second electrode in the first area; a first insulating layer in the first area and the second area; and a second insulating layer on the first insulating layer, wherein the first insulating layer includes a first opening in the second area, the second insulating layer includes a second opening overlapping the first opening, and a width of the first opening in a first direction is greater than a width of the second opening in the first direction.