Improved Manufacturing of Functional Elements with Reliable Electrode Connections
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Summary
Problems
Existing methods for manufacturing functional elements, such as photoelectric conversion elements, face challenges in yield due to issues with electrode exposure and film formation processes, leading to potential electrode removal or connection failures during the manufacturing process.
Innovation solutions
A method involving a substrate with exposed first and second electrodes, where a first film with gaps is formed over the substrate, allowing a second film to fill these gaps and protect the electrodes during the removal of the functional layer, thereby preventing electrode loss and ensuring proper electrical connection.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If a separate adhesive application process is used to join the diaphragm to the support, then the diaphragm can be securely fixed, but the manufacturing complexity and number of steps increase
Why choose this principle:
The patent combines the diaphragm and support into a single integrated component where the diaphragm is directly formed on the support surface. This merging eliminates the need for separate adhesive application processes and multiple manufacturing steps, while maintaining secure fixation through direct structural integration. The diaphragm and support function as a unified resonating system, simplifying both manufacturing and assembly.
Principle concept:
If multiple separate components are used for the resonating system, then each component can be optimized independently, but the assembly complexity and potential misalignment increase
Why choose this principle:
By integrating the diaphragm directly onto the support structure, the patent eliminates assembly operations and potential misalignment issues between separate components. The unified structure ensures precise alignment by definition, as there are no separate parts to align. The design maintains optimization capabilities through material selection and geometric design of the integrated component.
Application Domain
Data Source
AI summary:
A method involving a substrate with exposed first and second electrodes, where a first film with gaps is formed over the substrate, allowing a second film to fill these gaps and protect the electrodes during the removal of the functional layer, thereby preventing electrode loss and ensuring proper electrical connection.
Abstract
A method for manufacturing a functional element includes: preparing a substrate at an upper surface of which a first electrode and a second electrode are exposed; forming a first film above the substrate, the first film being provided with a gap where at least part of an upper surface of the first electrode is exposed; forming a second film on the first electrode, the second electrode, and the first film using a coating method; exposing the upper surface of the first electrode by removing a portion of the second film that is on the first electrode; and forming an electric contact 15 on the upper surface of the first electrode.