Display Bank Pattern With Variable Insulation for LED Alignment
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Solution Overview
Problem
Existing display devices face challenges in aligning light emitting elements efficiently and reducing manufacturing costs and time, particularly in forming insulation layers and bank patterns simultaneously.
Innovation Solution
A display device design that includes a substrate with alternately arranged areas, a first and second electrode, a first insulation layer with varying thicknesses, and a bank pattern integrally formed with the insulation layer, allowing for improved alignment and concurrent formation of insulation and bank patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If insulation layer and bank pattern are formed separately, then manufacturing precision is maintained, but manufacturing time and cost increase
Solution Approach 1:
The patent combines the insulation layer and bank pattern into a single integrated structure formed by one coating process. The bank pattern is created by forming protrusions on the insulation layer through a single photoresist coating and curing step, eliminating the need for separate formation processes and reducing manufacturing time while maintaining structural integrity.
Solution Approach 2:
The insulation layer serves multiple functions simultaneously: it provides electrical insulation, defines the bank pattern structure through its protrusions, and guides light emitting element placement. This multi-functional design eliminates the need for separate bank pattern structures, reducing process steps while maintaining manufacturing precision.
2Ease of manufacture
If bank pattern is formed separately, then alignment precision is maintained, but manufacturing cost increases
Solution Approach 1:
The bank pattern is merged with the insulation layer formation process, using the same photoresist coating and curing steps. This integration reduces material costs and processing costs while the protrusions on the insulation layer maintain precise alignment guidance for light emitting elements, achieving both cost reduction and precision maintenance.
3Manufacturing precision
If insulation layer has uniform thickness, then manufacturing simplicity is maintained, but light emitting element alignment is insufficient
Solution Approach 1:
The insulation layer features localized thickness variations with protrusions at specific positions rather than uniform thickness throughout. These localized protrusions provide precise alignment guidance for light emitting elements while the rest of the insulation layer maintains its insulating function, achieving improved alignment without excessive overall structural complexity.
Data Source
AI summary
A display device includes: a substrate including first areas and second areas alternately arranged in a first direction in a plane view; a first electrode and a second electrode on the substrate and spaced apart from each other in a second direction crossing the first direction; a first insulation layer on the substrate and covering the first electrode and the second electrode; and a light emitting element on the first insulation layer and electrically connected to the first electrode and the second electrode, the first insulation layer having a first thickness in the first area and a second thickness thicker than the first thickness in the second area, and the light emitting element being located in the first area.