Display Electrode and Insulation Layout With Fewer Photo Masks
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Solution Overview
Problem
Existing display device manufacturing processes are complex and costly due to the need for multiple masks and photo processes to form electrodes, insulation patterns, and intermediate electrodes.
Innovation Solution
A simplified manufacturing method for display devices that reduces the number of masks and photo processes by forming the third electrode and first insulation pattern using the same mask, allowing for the omission of the second insulation pattern and reduction in the number of photo processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks and photo processes are used to form electrodes and insulation patterns separately, then the manufacturing precision and reliability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the formation of the third electrode and first insulation pattern into a single photo process using the same mask. The mask simultaneously defines both the electrode pattern and the insulation pattern, merging two separate manufacturing steps into one, thereby reducing process complexity while maintaining the required precision for both structures
Solution Approach 2:
The mask serves multiple functions: it defines the third electrode pattern, defines the first insulation pattern, and enables the omission of the second insulation pattern. This multi-functionality reduces the total number of masks and photo processes needed, simplifying the overall manufacturing process
2Manufacturing precision
If multiple masks and photo processes are used to form electrodes and insulation patterns separately, then the manufacturing precision is improved, but the loss of time and productivity decrease
Solution Approach 1:
By merging the formation of the third electrode and first insulation pattern into a single photo process, the manufacturing cycle time is reduced. Instead of performing separate photo processes for each structure, both are created simultaneously in one step, directly addressing the time loss issue
3Manufacturing precision
If multiple masks and photo processes are used to form electrodes and insulation patterns separately, then the manufacturing precision is improved, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple photo processes into one, reducing the number of masks required. This consolidation directly lowers material costs (fewer masks) and process costs (fewer photo process steps), making the manufacturing more cost-effective while preserving precision through proper mask design
Solution Approach 2:
The invention discards the need for the second insulation pattern entirely by designing the first insulation pattern to extend beyond the third electrode. This elimination of unnecessary structures reduces material usage and simplifies the manufacturing process, thereby reducing costs
Data Source
AI summary
A display device includes a first electrode and a second electrode spaced apart from each other on a substrate, a light-emitting element disposed between the first electrode and the second electrode on the substrate, a third electrode disposed on the first electrode and an end of the light-emitting element, a fourth electrode disposed on the second electrode and another end of the light-emitting element, a first insulation pattern disposed on the third electrode, and a second insulation pattern disposed on the first insulation pattern. An end of the first insulation pattern corresponding to the end of the light-emitting element protrudes toward the another end of the light-emitting element further than an end of the third electrode, and the second insulation pattern fills a space adjacent to the end of the third electrode and formed under the first insulation pattern.