Display Device Bank Patterns Prevent Light Emitting Element Aggregation
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Solution Overview
Problem
Display devices face issues with lighting defects and reduced luminance due to aggregation of light emitting elements during alignment, leading to contact failures and compromised display quality.
Innovation Solution
The implementation of a display device design featuring bank patterns and electrodes on a substrate, with light emitting elements aligned on the sides of these patterns and connection electrodes contacting them within a via groove, preventing aggregation and enhancing light emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light emitting elements are aligned in a conventional manner, then the alignment process is simple, but light emitting elements aggregate causing lighting defects and reduced luminance
Solution Approach 1:
The alignment structure is segmented into multiple bank patterns (first bank pattern, second bank pattern, third bank pattern, fourth bank pattern) that divide the alignment space into distinct regions. Each bank pattern creates separate alignment zones that prevent light emitting elements from aggregating in single locations, thereby improving lighting quality while maintaining a manageable structural complexity through modular repetition
Solution Approach 2:
Different bank patterns are positioned at specific locations (first and second bank patterns at initial positions, third and fourth bank patterns at final positions) to create localized alignment control. This local quality approach ensures that light emitting elements are distributed uniformly across different regions, preventing aggregation and improving luminance without requiring complete restructuring of the entire alignment system
2Illumination intensity
If light emitting elements are densely packed to increase luminance, then brightness improves, but contact failures occur due to aggregation
Solution Approach 1:
The bank patterns segment the dense packing into controlled groups, where each segment (region between bank patterns) maintains optimal density for luminance while the segmentation itself prevents aggregation-induced contact failures. This allows high luminance through controlled density while preserving contact reliability through spatial distribution
Solution Approach 2:
The bank patterns act as intermediary structures that mediate between the need for dense packing (for luminance) and the need to prevent aggregation (for contact reliability). These intermediate bank patterns create controlled spacing and distribution, enabling both high brightness and reliable electrical contacts by preventing direct aggregation of light emitting elements
3Reliability
If bank patterns are added to prevent aggregation, then lighting quality improves, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct stages corresponding to the placement of different bank patterns (initial position bank patterns, final position bank patterns). This segmentation allows each bank pattern to be manufactured and positioned separately using existing manufacturing techniques, improving lighting quality through controlled distribution while avoiding the need for completely new manufacturing processes
Solution Approach 2:
Bank patterns are prepared and positioned in advance at initial and final positions before light emitting element placement. This preliminary action of pre-positioning bank patterns simplifies the overall manufacturing process by establishing the alignment framework beforehand, making the subsequent element placement more straightforward and reducing the complexity of real-time alignment operations
Data Source
AI summary
A display device includes a plurality of bank patterns disposed on a substrate and spaced apart from each other, a plurality of electrodes disposed on the substrate and extended parallel to each other and spaced apart from each other, an insulating layer disposed on the plurality of electrodes and the plurality of bank patterns, and a plurality of light emitting elements disposed on the insulating layer, having both ends disposed on the plurality of electrodes, wherein the plurality of bank patterns include sides facing each other, and portions of the plurality of light emitting elements are disposed on the sides of the plurality of bank patterns.