Sub-10 μm Pixel Spacing via Resist Mask Patterning
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Solution Overview
Problem
Current display devices face challenges in achieving high-resolution, high-definition, and high-aperture ratio displays due to limitations in manufacturing methods, particularly with the use of metal masks which result in inaccuracies and increased leakage current, making it difficult to reduce the distance between light-emitting devices to achieve high resolution and reliability.
Innovation Solution
The display device incorporates island-shaped light-emitting units with a sacrificial layer and insulators to reduce the distance between light-emitting devices, using a resist mask to process the EL layer deposited over the entire surface, allowing for closer pixel spacing and improved reliability by preventing short circuits and leakage current, and employing a tandem structure with charge-generation layers for enhanced luminance and power efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal masks are used to manufacture light-emitting devices, then manufacturing process is simple, but manufacturing precision deteriorates and leakage current increases
Solution Approach 1:
The patent extracts and removes the metal mask from the manufacturing process entirely. Instead of using metal masks to define pixel patterns, the invention deposits the EL layer over the entire surface and then uses a resist mask to selectively remove portions, thereby eliminating the limitations of metal mask precision and enabling sub-10 μm pixel spacing without the harmful effects of metal mask-induced leakage current.
Solution Approach 2:
The patent inverts the conventional manufacturing approach by depositing the EL layer completely first and then using a resist mask to define the pixel pattern through selective removal, rather than using a metal mask to define the pattern during deposition. This inversion allows for higher precision and eliminates metal mask-related defects.
2Manufacturing precision
If distance between light-emitting devices is reduced to achieve high resolution, then manufacturing precision improves, but leakage current increases and reliability deteriorates
Solution Approach 1:
The patent introduces a resist mask as an intermediary material to define the pixel pattern after EL layer deposition. This resist mask allows for precise sub-10 μm pixel spacing to be achieved without the leakage current problems associated with metal masks, as the resist mask can be precisely patterned and removed without causing electrical defects.
Solution Approach 2:
The resist mask is used as a temporary, disposable element in the manufacturing process. It is deposited, patterned, used to define the pixel structure, and then removed, leaving no harmful residues. This disposable approach enables high-precision pixel spacing without the persistent leakage current issues caused by metal masks.
3Illumination intensity
If aperture ratio is increased to improve display brightness, then luminance improves, but manufacturing precision deteriorates due to difficulty in reducing pixel spacing
Solution Approach 1:
The patent replaces the mechanical metal mask system with a chemical/resist-based patterning system. This substitution enables much finer pixel spacing control (sub-10 μm) through photolithography techniques, thereby allowing for higher aperture ratios and improved display brightness without the manufacturing precision limitations of mechanical metal masks.
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
This approach enables the production of high-resolution, high-aperture ratio display devices with improved reliability by reducing pixel spacing to less than 10 μm and utilizing a tandem structure for increased luminance and reduced power consumption.
Implementation Method 1
By applying voltage to this element, light emission can be obtained from the light-emitting organic compound
Implementation Method 2
the first coloring layer and the second coloring layer have a function of transmitting visible light of different colors
Data Source
AI summary
A high-resolution display device is provided. The display device includes first and second light-emitting devices, first and second coloring layers, and first, second, and third insulators; the first coloring layer is positioned to overlap with the first light-emitting device; the second coloring layer is positioned to overlap with the second light-emitting device; the first light-emitting device and the second light-emitting device have a function of emitting white light; the first coloring layer and the second coloring layer have a function of transmitting visible light of different colors; the first light-emitting device includes a first conductive layer and a first light-emitting layer over the first conductive layer; the second light-emitting device includes a second conductive layer and a second light-emitting layer over the second conductive layer; the first insulator is in contact with at least part of a side surface of the first light-emitting device; the second insulator is in contact with at least part of a side surface of the second light-emitting device; the first insulator and the second insulator are positioned over the third insulator; and the third insulator is positioned to cover an end portion of the first conductive layer and an end portion of the second conductive layer.