Display Electrode Contact Structure With Gap-Filling Insulation
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Solution Overview
Problem
Inorganic light emitting diodes face issues with interface defects and gaps in the insulating layer, leading to potential damage to light emitting elements and poor contact with electrodes during the manufacturing process of display devices.
Innovation Solution
An organic insulating layer is formed on top of an inorganic insulating layer to fill defects and gaps, ensuring proper alignment and contact of light emitting elements, thereby preventing disconnection and short-circuit failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an inorganic insulating layer is used to fix the light emitting element, then the light emitting element can be aligned and fixed, but interface defects (seams) and gaps are formed around and below the light emitting element
Solution Approach 1:
The patent uses a composite insulating layer structure combining inorganic and organic materials. The inorganic insulating layer (e.g., silicon oxide, silicon nitride) provides fixing reliability and alignment, while the organic insulating layer (e.g., benzocyclobutene, polyimide) fills the interface defects and gaps formed by the inorganic layer, creating a composite structure that achieves both fixing reliability and interface quality
Solution Approach 2:
The organic insulating layer acts as an intermediary substance that fills the gaps and defects between the inorganic insulating layer and the light emitting element. This intermediary layer eliminates the harmful effects of interface defects while maintaining the structural support provided by the inorganic layer
2Ease of manufacture
If only an inorganic insulating layer is formed, then the manufacturing process is simpler, but gaps below the light emitting element cause damage or poor contact with electrodes
Solution Approach 1:
The organic insulating layer is formed in advance to fill gaps below the light emitting element before subsequent electrode formation processes. This preliminary action prevents potential damage and ensures good contact between the light emitting element and electrodes, avoiding the need for complex repair or adjustment processes later
3Reliability
If an inorganic insulating layer is used, then the light emitting element can be covered and protected, but crystal defects and gaps lead to short-circuit failures
Solution Approach 1:
The patent converts the harmful gaps and defects in the inorganic insulating layer into beneficial features by filling them with the organic insulating layer. The organic material fills the voids and defects that would otherwise cause short-circuits, transforming the harmful incomplete coverage into a benefit by creating a complete, defect-free insulating structure
Data Source
AI summary
A display device and method of manufacturing a display device. The display device includes a first electrode, a second electrode facing the first electrode, a first insulating layer on the first electrode and the second electrode and between the first electrode and the second electrode, a light emitting element on the first insulating layer, a second insulating layer covering the light emitting element and exposing end portions of the light emitting element, a third insulating layer on the second insulating layer, a first contact electrode electrically connected to the first electrode, on the third insulating layer and in contact with a first end portion of the light emitting element exposed by the second insulating layer, and a second contact electrode electrically connected to the second electrode, on the third insulating layer and in contact with a second end portion of the light emitting element exposed by the second insulating layer.