Vertical Sub-Pixel Structure for Aperture Ratio and Yield
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Solution Overview
Problem
Existing display device repair methods result in a loss of aperture ratio and require cutting or removal of structures, leading to reduced product yield and increased process time.
Innovation Solution
A display device with a vertical sub-pixel structure and side mirrors is proposed, which minimizes aperture area loss by changing the sub-pixel structure from horizontal to vertical and increases light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional horizontal sub-pixel structure is used, then manufacturing process is simple, but aperture ratio loss occurs and product yield decreases
Solution Approach 1:
The patent transitions from a traditional horizontal sub-pixel structure to a vertical sub-pixel structure by stacking multiple anode electrodes (first sub anode electrode and second sub anode electrode) in the vertical direction. This dimensional change allows the light-emitting area to be maintained or increased while reducing the lateral footprint, thereby improving aperture ratio and product yield without significantly complicating the manufacturing process.
Solution Approach 2:
The patent implements a nested structure where the second sub anode electrode is positioned on top of the first sub anode electrode, with the second overcoat layer covering portions of the first sub anode electrode. This nesting arrangement allows multiple functional layers to be integrated within a compact vertical space, maximizing the use of available area for light emission while maintaining structural integrity and simplifying the overall manufacturing approach.
2Ease of repair
If traditional repair methods are used, then defect correction is possible, but aperture ratio is reduced and process time increases
Solution Approach 1:
The patent incorporates a second sub anode electrode and second overcoat layer during the initial manufacturing process, creating a pre-configured structure that allows for future repair operations. The second overcoat layer is specifically designed to cover portions of the first sub anode electrode while exposing other portions, creating ready-access points for defect correction without requiring additional processing steps later.
3Illumination intensity
If vertical sub-pixel structure with side mirrors is implemented, then light extraction efficiency increases, but device complexity increases
Solution Approach 1:
The patent introduces side mirrors with asymmetric positioning and orientations within the vertical sub-pixel structure. These mirrors are strategically placed to reflect light from the organic light emitting layer toward the emission direction, enhancing light extraction efficiency. The asymmetric configuration allows selective optimization of light extraction from different regions without requiring symmetric complexity throughout the entire structure.
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 proposed solution improves product yield by reducing aperture ratio reduction and increases light extraction efficiency, resulting in a low-power display device.
Implementation Method 1
a second overcoat layer on a portion of the first sub anode electrode in the emissive area, the second overcoat layer including an upper surface and an inclined side surface that extends from the upper surface to the first sub anode electrode
Implementation Method 2
an organic light emitting layer covering the first sub anode electrode, the second overcoat layer, and the second sub anode electrode in the emissive area
Data Source
AI summary
A display device and a method of repairing the display device is disclosed. The display device includes a substrate and a plurality of sub-pixels arranged on the substrate. A sub-pixel includes an emissive area and a circuit area, a first overcoat layer on the substrate, a 1-1 electrode arranged on the first overcoat layer, a second overcoat layer covering at least a portion of the 1-1 electrode, and a 1-2 electrode arranged on the second overcoat layer, a light emitting layer on the 1-1 electrode, the 1-2 electrode and the second overcoat layer, and a cathode electrode on the light emitting layer.