Stacked EL Layer Display Device Insulating Resin Alignment
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Solution Overview
Problem
Current display devices face challenges in achieving high resolution, low power consumption, high contrast, and reliable manufacturing with existing technologies, particularly in forming light-emitting elements without the use of shadow masks which can lead to deviations and defects.
Innovation Solution
A display device structure incorporating an insulating layer between light-emitting layers of different colors, using a resin or its precursor, and a common electrode shared among pixels, allows for precise alignment and separate formation of EL layers without a shadow mask, enhancing resolution and aperture ratio while reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If shadow masks are used to form light-emitting elements, then manufacturing process is simple, but manufacturing precision deteriorates due to deviations and defects
Solution Approach 1:
The patent removes the shadow mask from the manufacturing process entirely. Instead of using a shadow mask to define pixel patterns, the invention forms EL layers directly on pixel electrodes through controlled material deposition, eliminating the source of alignment deviations and defects associated with shadow masks.
Solution Approach 2:
The patent replaces the mechanical shadow mask system with a material deposition-based formation method. Rather than using physical masks to block and define patterns, the invention uses controlled deposition of EL materials directly onto pixel electrodes, achieving both simplicity and high precision.
2Manufacturing precision
If EL layers of different colors are formed separately, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent segments the display into individual pixel elements, with each pixel containing its own EL layer formed separately on corresponding pixel electrodes. This segmentation allows precise control of each pixel's light-emitting characteristics while maintaining overall device simplicity through modular architecture.
Solution Approach 2:
The patent applies local quality by forming EL layers with specific materials and properties directly on each pixel electrode region. Each pixel's EL layer is optimized for its specific function, allowing different colors and characteristics in different regions without affecting other pixels, thus achieving high precision without overall complexity.
3Illumination intensity
If aperture ratio is increased, then display quality is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent enables self-service alignment where the EL layer formation process automatically aligns with the pixel electrode pattern. The material deposition is controlled to form EL layers precisely on the pixel electrodes, eliminating the need for separate alignment steps and reducing manufacturing precision requirements while maintaining high aperture ratio.
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, low-power consumption display devices with improved contrast and reliability by minimizing defects and increasing the aperture ratio, allowing for higher pixel density and efficient light emission.
Implementation Method 1
the insulating layer includes a resin or a precursor of the resin, and the insulating layer includes a region sandwiched between a first end face of the first EL layer and a second end face of the second EL layer
Data Source
AI summary
A display device with high display quality is provided. A highly reliable display device is provided. A display device with low power consumption is provided. A display device that can easily achieve a higher resolution is provided. A display device with both high display quality and a high resolution is provided. A display device with high contrast is provided. The display device includes an insulating layer, a first lower electrode, a first EL layer over the first lower electrode, a second lower electrode, a second EL layer over the second lower electrode, and an upper electrode over the first EL layer, over the second EL layer, and over the insulating layer. The first EL layer includes a first light-emitting layer, the second EL layer includes a second light-emitting layer, the first EL layer and the second EL layer are adjacent to each other, the insulating layer includes a resin or a precursor of the resin, and the insulating layer includes a region sandwiched between a first end face of the first EL layer and a second end face of the second EL layer.