Non-Overlapping Sub-Pixel Layout for Simpler Display Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in manufacturing display devices with high-performance light emitting elements is the increased complexity and cost of the manufacturing process due to the miniaturization of light emitting elements, which requires additional processing steps.
Innovation Solution
The proposed solution involves a display device design where the light emitting element area and the sub-pixel area do not overlap, allowing for a simplified manufacturing process and reduced costs. This design includes a first reflective layer covering the light emitting element, a second reflective layer in the sub-pixel area, and a color conversion layer with quantum-dots, which are strategically positioned to enhance light emission and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the size of the light emitting element is decreased to implement high performance display device, then the display performance is improved, but the manufacturing process complexity increases and process cost increases
Solution Approach 1:
The patent divides the pixel structure into distinct light emitting element area and sub-pixel area that do not overlap in plan view. This segmentation allows independent optimization of each area, simplifying the manufacturing process while maintaining high display performance through miniaturized light emitting elements.
Solution Approach 2:
The patent transitions from a conventional overlapping two-dimensional layout to a separated spatial arrangement where the light emitting element area and sub-pixel area are positioned in different planar regions. This dimensional reorganization eliminates the need for additional processing steps while achieving miniaturization goals.
2Illumination intensity
If the size of the light emitting element is decreased to implement high performance display device, then the display performance is improved, but the process cost increases due to additional process steps
Solution Approach 1:
By segmenting the pixel into non-overlapping light emitting element area and sub-pixel area, the patent eliminates the need for additional alignment and patterning processes that would increase cost, while still achieving the desired miniaturization for high performance display.
Solution Approach 2:
The separated area structure serves multiple functions simultaneously: it enables miniaturization of light emitting elements for high performance while providing dedicated space for sub-pixel structures, all within a simplified single-layer manufacturing process that reduces overall production cost.
3Ease of manufacture
If the light emitting element area and sub-pixel area do not overlap in plan view, then the manufacturing process is simplified and process cost is reduced, but the area utilization may be affected
Solution Approach 1:
The patent resolves the area utilization concern by transitioning to a separated planar arrangement where light emitting element area and sub-pixel area occupy different regions. This dimensional reorganization maintains high area utilization while enabling simplified single-layer manufacturing without overlapping complexity.
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 simplifies the manufacturing process, reduces costs, and expands the emission area of the light emitting elements, leading to improved light efficiency and display performance.
Implementation Method 1
a first reflective layer covering at least a portion of the light emitting element... Light emitted by the light emitting element included in the first sub-pixel portion may be guided in a light output direction of the display device by the first reflective layer
Implementation Method 2
a second reflective layer disposed in the sub-pixel area... the second reflective layer may include a reflective surface facing a light output direction of the display device
Implementation Method 3
a color conversion layer disposed on the second reflective layer in the sub-pixel area and may include a quantum-dot
Data Source
AI summary
A display device and a method of manufacturing the display device, the display device may include a sub-pixel portion disposed on a base layer and may include a light emitting element area where a light emitting element may be disposed and a sub-pixel area. The light emitting element area and the sub-pixel area may not overlap each other in a plan view.