Display Apparatus Varying Organic Layer Thickness
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Solution Overview
Problem
Existing display apparatus technologies face challenges in achieving high resolution due to deviations in the design and position of light-emitting layers caused by low dimensional accuracy and misalignment of fine metal masks, leading to reduced manufacturing yield and reliability.
Innovation Solution
A display apparatus with a microcavity structure and sacrificial layers, where the thickness of organic compound layers is varied to achieve precise alignment and patterning, using photolithography and sacrificial layers to maintain planarity and prevent disconnection of conductive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fine metal mask is used to form light-emitting layers, then patterning can be achieved, but dimensional accuracy deteriorates due to mask deviation and misalignment
Solution Approach 1:
The patent introduces an intermediary alignment mark structure that mediates between the mask positioning system and the final light-emitting layer pattern. This alignment mark serves as a reference intermediary that allows for precise positioning and compensation of mask deviations, thereby maintaining both patterning capability and dimensional accuracy simultaneously.
2Reliability
If the thickness of organic compound layers is varied for different light-emitting devices, then microcavity structure performance is improved, but layer formation complexity increases
Solution Approach 1:
The patent applies local quality by varying the thickness of organic compound layers at different spatial locations corresponding to different light-emitting devices. Each region has a specifically optimized layer thickness tailored to its microcavity requirements, while the overall formation process remains systematic and controllable through localized deposition parameters.
3Reliability
If photolithography and sacrificial layers are used to maintain planarity, then manufacturing reliability is improved, but process complexity increases
Solution Approach 1:
The patent employs preliminary action by forming sacrificial layers and alignment marks before the final light-emitting layer deposition. These preliminary structures prepare the substrate in advance with proper planarity and positioning references, enabling subsequent layers to be formed with high precision without requiring complex real-time adjustments during the main deposition process.
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
The solution enables the production of high-resolution and highly reliable display apparatus by minimizing deviations and ensuring precise layer formation, thereby improving manufacturing yield and reliability.
Implementation Method 1
using photolithography and sacrificial layers to maintain planarity and prevent disconnection of conductive layers
Data Source
AI summary
A high-resolution display apparatus is provided. The display apparatus includes a first light-emitting device, a second light-emitting device positioned next to the first light-emitting device, a third light-emitting device positioned next to the second light-emitting device, a first insulating layer, and a second insulating layer. The first insulating layer includes a first region between the first light-emitting device and the second light-emitting device and a second region between the second light-emitting device and the third light-emitting device. The second insulating layer includes a region positioned over a lower electrode of the third light-emitting device. A thickness of a third organic compound layer of the third light-emitting device is different from a thickness of a first organic compound layer of the first light-emitting device. The thickness of the third organic compound layer of the third light-emitting device is different from a thickness of a second organic compound layer of the second light-emitting device. In a cross-sectional view, the first insulating layer is provided so that a height from a bottom surface of the lower electrode of the third light-emitting device is equal to a height from a bottom surface of a lower electrode of the second light-emitting device.