Abstract: The method for producing an OLED micro-display on a silicon wafer uses a collimating shadow mask formed on a silicon substrate. The mask is fabricated by depositing a material layer on the front side and on the back side of the substrate and etching a portion of the layer on the back side of the substrate to a reduced thickness of at least 20 microns. At least one opening is created in the etched portion of the substrate. The substrate beneath the opening is removed to create the mask. The mask is situated at a location spaced from the surface of the silicon wafer and exposed to a linear evaporation source. Organic layers are then deposited on the silicon wafer in a location aligned with the mask opening.

Abstract: An apparatus and method for performing material deposition on an active-matrix organic light emitting diode (AMOLED) display array on a substrate, includes aligning a shadow mask to a first position relative to the substrate; initially depositing a first material through the shadow mask onto the substrate at a first material deposition position relative to the first position of the aligned shadow mask and at a first deposition height; incrementing the position the shadow mask to a second position relative to the first material deposition position; and subsequently depositing one of the first material or a second material through the shadow mask onto the substrate at a second material deposition position relative to the first material deposition position, wherein the second material deposition position having an identical deposition pattern as the first material deposition position on account of the shadow mask.

Abstract: An immersive headset device is provided that includes a display portion and a body portion. The display portion may include microdisplays having a compact size. The microdisplays may be movable (e.g., rotational) relative to the body portion and can be moved (e.g., rotated) between a flipped-up position and a flipped-down position. In some instances, when the microdisplays are flipped up, the headset provides an augmented reality (AR) mode to a user, and when the microdisplays are flipped down, the headset provide a virtual reality (VR) mode to the user. In certain implementations, the headset includes an electronics source module to provide power and/or signal to the microdisplays. The electronics source module can be attached to a rear of the body portion in order to provide advantageous weight distribution about the head of the user.

Abstract: A method of active alignment of a shadow mask to a substrate includes a first alignment by moving the shadow mask and the substrate a first distance in a vertical direction, capturing a first alignment image, determining at least one of a first correction distance and a first rotational correction angle, and aligning the shadow mask and the substrate by moving the first correction distance and rotating the first rotational correction angle. The method further includes performing a first material deposition process on the substrate and continuously capturing a first series of alignment images during the generation of the first material deposition flow. During the generation of the first material deposition flow the first series of alignment images are analyzed to determine a second correction distance and a second rotational correction angle and determining whether second distance and/or rotational correction angle is greater than or equal to a predetermined value to cause a second alignment process to occur.

Abstract: A tandem Organic Light Emitting Diode (OLED) apparatus and method of fabricating the same, where the tandem OLED apparatus includes a buffer assisted charge generation layer having a junction of a p-type doped semiconductor layer and an n-type doped semiconductor layer, where a hole buffer layer and an electron buffer layer pair surrounding the junction of the p-type and n-type doped semiconductor layers. The OLED apparatus further includes a first OLED emissive layer and a second OLED emissive layer pair surrounding the buffer assisted charge generation layer, and a cathode and anode layer pair further surrounding the first and second OLED emissive layer pair.

Abstract: A direct-deposition system capable of forming a high-resolution pattern of material on a substrate is disclosed. Vaporized atoms from an evaporation source pass through a pattern of through-holes in a shadow mask to deposit on the substrate in the desired pattern. The shadow mask is held in a mask chuck that enables the shadow mask and substrate to be separated by a distance that can be less than ten microns. As a result, the vaporized atoms that pass through the shadow mask exhibit little or no lateral spread (i.e., feathering) after passing through its apertures and the material deposits on the substrate in a pattern that has very high fidelity with the aperture pattern of the shadow mask.

Abstract: A full-color display panel is provided comprising a repeating super-pixel block including four pixel units, wherein each of the pixel units has a first sub-pixel configured to emit a first color light, a second sub-pixel configured to emit a second color light, and a third sub-pixel configured to emit a third color light. The first or second sub-pixel abuts the same-color sub-pixel of the adjacent pixel unit thereof to form at least a double-sized sub-pixel area. The third sub-pixel abuts the same-color sub-pixel of all adjacent pixel units thereof to form at least a quadruple-sized sub-pixel area. The first color light, the second color light, and the third color light are one of emitted through or from respective organic layers of the first color sub-pixel, the second color sub-pixel and the third color sub-pixel.

Abstract: A high efficacy multi-layer seal structure formed on an organic light emitting diode device and the process for depositing the same. A thin film seal is formed over the substrate having OLED layers, and includes a first metallic layer formed over the substrate, an inorganic layer formed over the first metallic layer, and a second metallic layer formed of the inorganic layer. The metallic layers comprise one or more oxide or nitride layers, each oxide or nitride comprising a metal. The inorganic layer comprises a metal oxide, a metal nitride or a metal oxynitride. The process for forming the multi-layer seal structure includes depositing the first metallic layer over the substrate using atomic layer deposition, depositing the inorganic layer over the first metallic layer using sputtering, and then depositing the second metallic layer over the inorganic layer using atomic layer deposition.

Abstract: An OLED microdisplay comprising a substrate, a pixel array and a patterned conductive layer underneath the anode pad array to form an effective ground plane in order to greatly reduce or eliminate electrical cross-talk between pixels, and a method for fabricating same.

Abstract: A direct-deposition system capable of forming a high-resolution pattern of material on a substrate is disclosed. Vaporized atoms from an evaporation source pass through an aperture pattern of a shadow mask to deposit on the substrate in the desired pattern. Prior to reaching the shadow mask, the vaporized atoms pass through a collimator that operates as a spatial filter that blocks any atoms not travelling along directions that are nearly normal to the substrate surface. As a result, the vaporized atoms that pass through the shadow mask exhibit little or no lateral spread (i.e., feathering) after passing through its apertures and the material deposits on the substrate in a pattern that has very high fidelity with the aperture pattern of the shadow mask. The present invention, therefore, mitigates the need for relatively large space between regions of deposited material normally required in the prior art, thereby enabling high-resolution patterning.

Abstract: A system and method for repairing an OLED display having an array of OLED pixels including at least one inoperative OLED pixel, wherein each OLED pixel is controlled by a pixel driver circuit having a fusible element. The system includes a first switch for reducing an energizing signal to the OLED pixel array, the energizing signal exceeding a threshold level below which the OLED pixels should not emit light. A second switch is provided for increasing a bias signal to the OLED pixel array, the bias signal exceeding a threshold level above which the fusible element of the inoperative OLED pixels are blown, such that inoperative OLED pixels no longer emit light.

Abstract: An image rendering system comprising a pixel array and variable-density column and row scanner circuits is disclosed. The variable-density column and row scanner circuits enable software-based reconfiguration of the active display area within the available screen area of the display. In addition, a hardware restore-to-black function is provided that enables pixels outside of the desired image region to be driven to black without their requiring image data or excitation. As a result, the functionality of the functionality of the display can be reconfigured to match the desired image region on a frame-by-frame basis. Therefore, displays in accordance with the present invention can operate at higher frame rates and with less power consumption that prior-art displays.

Abstract: An organic light-emitting diode (OLED) display device is provided having a color emission layer including a plurality of organic light-emitting elements in a first arrangement and an electronics layer. The electronics layer includes a plurality of pixel drive circuits each including an electrode contact. The electronics layer includes a plurality of independently addressable sub-regions each sub-region including an identical pattern of electrode contacts created using a single reticle exposure. Each sub-region is orientated differently within a plane such that the first arrangement of light-emitting elements is electrically connected to the patterned electronics layer.

Abstract: A method of fabricating an active matrix display is disclosed in which one or more oxide thin film transistors is monolithically integrated with an inorganic light emitting diode structure. The method comprises forming an array of inorganic light emitting diodes over a substrate defining a plurality of sub-pixels, depositing an insulating layer over the inorganic LED array, forming conductive vias through the insulating layer, one via for each LED in the LED array, and forming a metal oxide thin film transistor backplane, including an array of pixel driver circuits, over the dielectric layer and conductive vias, wherein one driver circuit electrically controls each sub-pixel through the dielectric layer.

Abstract: An immersive headset device is provided that includes a display portion and a body portion. The display portion may include microdisplays having a compact size. The microdisplays may be movable (e.g., rotational) relative to the body portion and can be moved (e.g., rotated) between a flipped-up position and a flipped-down position. In some instances, when the microdisplays are flipped up, the headset provides an augmented reality (AR) mode to a user, and when the microdisplays are flipped down, the headset provide a virtual reality (VR) mode to the user. In certain implementations, the headset includes an electronics source module to provide power and/or signal to the microdisplays. The electronics source module can be attached to a rear of the body portion in order to provide advantageous weight distribution about the head of the user.

Abstract: An active-matrix organic light-emitting diode microdisplay device having a temperature control system including a temperature sensor and a control means for regulating the temperature of the OLED. The temperature is regulated by a bias transistor within the circuit, operating as a function of the temperature of the panel, such that low panel temperatures cause an increase in voltage of the bias transistor which draws a higher current through the top voltage drive transistor for self-heating the area surrounding the OLED.

Abstract: A color display is provided that includes a light emitting sub-pixel and a filter layer including first and second color filter materials. The first color filter material is adapted to reduce transmittance of visible light outside a first transmittance spectrum corresponding to a first color, and the second color filter material is adapted to reduce transmittance of visible light outside a second transmittance spectrum corresponding to a second color. The second color is different than the first color. A color display having a white-balanced pixel is provided. A method of white-balancing a light emitting device is provided. A method of reducing unwanted light output due to electrical leakage is provided to fall below a pre-determined threshold. An opaque layer may be interposed between the sub-pixels and/or may frame illuminated areas of sub-pixels, and may be a combination of red, green, and/or a blue filter material.

Abstract: A method of making a patterned OLED layer or layers. The method uses a shadow mask having, for example, a free-standing silicon nitride membrane to pattern color emitter material with a feature size of less than 10 microns. The methods can be used, for example, in the manufacture of OLED microdisplays.

Abstract: An immersive headset device is provided that includes a display portion and a body portion. The display portion may include microdisplays having a compact size. The microdisplays may be movable (e.g., rotational) relative to the body portion and can be moved (e.g., rotated) between a flipped-up position and a flipped-down position. In some instances, when the microdisplays are flipped up, the headset provides an augmented reality (AR) mode to a user, and when the microdisplays are flipped down, the headset provide a virtual reality (VR) mode to the user. In certain implementations, the headset includes an electronics source module to provide power and/or signal to the microdisplays. The electronics source module can be attached to a rear of the body portion in order to provide advantageous weight distribution about the head of the user.

Abstract: A method of making a patterned OLED layer or layers. The method uses a shadow mask having, for example, a free-standing silicon nitride membrane to pattern color emitter material with a feature size of less than 10 microns. The methods can be used, for example, in the manufacture of OLED microdisplays.