Display Electrode Layout for Reliable Auxiliary Contact Openings
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Solution Overview
Problem
Existing display devices face challenges in achieving efficient electrical connections and reliable manufacturing processes, particularly in the formation of holes in intermediate layers, which can lead to connection failures between auxiliary electrodes and second electrodes, due to process restrictions and quality issues related to the size and positioning of openings in insulating layers.
Innovation Solution
A display device structure and manufacturing method involving a substrate with an organic insulating layer, a first electrode, an auxiliary electrode, a bank layer, and an intermediate layer with a hole that partially overlaps the organic insulating layer's opening, allowing for contact between the second electrode and the auxiliary electrode through the hole, while ensuring the hole's center is within the opening and spaced adequately from the insulating layer's edge, enhancing the contact area's quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hole is formed in the intermediate layer to connect the auxiliary electrode and the second electrode, then electrical connection is achieved, but the hole positioning and size control becomes difficult leading to connection failures
Solution Approach 1:
The patent introduces an auxiliary electrode as an intermediary element that extends into the emission layer to establish electrical connection with the second electrode. This auxiliary electrode serves as a mediator that bridges the connection between the first electrode structure and the second electrode, eliminating the need for precise hole formation through the intermediate layer while ensuring reliable electrical contact.
Solution Approach 2:
The patent divides the electrode structure into multiple segments: the first electrode, the auxiliary electrode extending into the emission layer, and the second electrode. This segmentation allows each component to perform its specific function independently, with the auxiliary electrode specifically tasked with establishing the critical electrical connection, thereby reducing the manufacturing precision requirements for hole formation.
2Productivity
If the opening in the organic insulating layer is made smaller to improve pixel density, then device integration increases, but the process restrictions for hole formation and electrode connection become more severe
Solution Approach 1:
The auxiliary electrode acts as an intermediary that extends into the emission layer to establish electrical connection, eliminating the need for precise hole formation through the organic insulating layer. This approach allows the opening size to be optimized for pixel density without compromising manufacturing ease, as the auxiliary electrode provides a robust connection path that is not sensitive to opening dimensions.
3Reliability
If the hole in the intermediate layer is positioned to maximize contact area, then electrical connection quality improves, but the positioning control becomes more difficult
Solution Approach 1:
The auxiliary electrode serves as an intermediary element that extends into the emission layer to establish electrical connection with the second electrode. This approach eliminates the need for precise hole positioning in the intermediate layer, as the auxiliary electrode provides a robust connection path that is not sensitive to positioning accuracy, thereby maintaining high electrical connection quality while simplifying manufacturing control.
Data Source
AI summary
A display device includes: a substrate; an organic insulating layer on the substrate and having an opening; a first electrode on the organic insulating layer; an auxiliary electrode on the organic insulating layer and including a first portion overlapping the opening; a bank layer having a first bank opening overlapping the first electrode and a second bank opening overlapping the first portion; an intermediate layer on the first electrode and the auxiliary electrode, the intermediate layer including a hole exposing a portion of the auxiliary electrode; and a second electrode on the intermediate layer, overlapping the first electrode and the auxiliary electrode, and in contact with the auxiliary electrode through the hole in the intermediate layer. The hole in the intermediate layer only partially overlaps the opening in the organic insulating layer and is located within the second bank opening in a plan view.