Auxiliary Electrode Thickness for Common Function Layer Formation
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Solution Overview
Problem
The existing display device manufacturing process is complicated and costly due to the need to remove a common function layer, such as an electron injection layer, from contact holes to allow direct contact between the second electrode and auxiliary wiring line, increasing manufacturing costs.
Innovation Solution
A display device with a light-emitting element layer featuring an edge cover film exposing the first electrode, a common second electrode shared among multiple light-emitting elements, and an auxiliary electrode with a greater film thickness than the upper common function layer, allowing the electron injection layer to be separated stepwise, simplifying the formation of the common function layer and reducing electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the common function layer is removed from contact holes to allow direct contact between the second electrode and auxiliary wiring line, then electrical connection is improved, but the manufacturing process becomes complicated and costly
Solution Approach 1:
The invention changes the film thickness parameter of the auxiliary electrode, making it greater than the film thickness of the upper common function layer. This parameter change allows the auxiliary electrode to protrude from the top surface of the common function layer, enabling direct electrical contact with the second electrode without removing the common function layer from contact holes, thus simplifying the manufacturing process while maintaining reliable electrical connection
Solution Approach 2:
The invention transitions from a planar contact approach to a three-dimensional contact approach by making the auxiliary electrode thicker than the upper common function layer. This dimensional change allows the auxiliary electrode to extend vertically above the common function layer, creating a contact path that bypasses the need to remove the common function layer, thereby simplifying the manufacturing process while ensuring electrical connection
2Reliability
If the common function layer is removed from contact holes, then direct electrical contact is achieved, but manufacturing cost increases
Solution Approach 1:
By changing the film thickness parameter of the auxiliary electrode to be greater than the upper common function layer, the invention enables direct electrical contact through vertical protrusion rather than through removal of the common function layer. This approach maintains manufacturing simplicity and reduces costs while achieving the desired electrical connection reliability
3Ease of manufacture
If the auxiliary electrode has greater film thickness than the upper common function layer, then the electron injection layer is separated stepwise simplifying the process, but the device structure becomes more complex
Solution Approach 1:
The invention uses a specific film thickness parameter relationship (auxiliary electrode thickness > upper common function layer thickness) to achieve stepwise separation of the electron injection layer during vapor deposition. This parameter-based approach simplifies the manufacturing process by eliminating the need for additional etching or removal steps, while the resulting stepped structure is an inherent outcome of the deposition process rather than an added 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 configuration simplifies the process of forming the common function layer, reduces manufacturing costs, and ensures efficient electrical connection between the second electrode and auxiliary electrode, improving the uniformity of in-plane brightness.
Implementation Method 1
a process of forming the common function layer (vapor deposition process)
Data Source
AI summary
A display device provided with a light-emitting element layer in which a plurality of light-emitting elements each including a first electrode, a function layer, and a second electrode are formed. An auxiliary electrode is provided on a lower side of an edge cover film covering an edge of the first electrode, a function layer includes a common function layer common to the plurality of light-emitting elements and individual function layers, each of which corresponding to each of the plurality of light-emitting elements, the common function layer includes an upper common function layer provided between the light-emitting layers included in the individual function layers, respectively, and the second electrode, and a film thickness of the auxiliary electrode is greater than a film thickness of the upper common function layer.