Display Electrode Layout for Fewer Masks and Better LED Integration
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Solution Overview
Problem
Current display device fabrication processes require multiple masks, increasing complexity and reducing efficiency, while existing technologies fail to optimize electrode configurations for improved light emitting element integration.
Innovation Solution
A display device design with reduced mask counts, featuring specific electrode configurations and a method of fabricating the device that includes forming electrodes on a substrate, aligning light emitting elements between them, and using photoresist and etching processes to create transparent and opaque conductive layers, with insulating patterns to enhance light emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the fabrication process, then manufacturing precision can be maintained, but device complexity and fabrication time increase
Solution Approach 1:
The patent combines multiple mask functions into a single mask structure. The mask includes a first mask pattern for defining electrode regions and a second mask pattern for defining light emitting element regions, allowing both patterning operations to be performed simultaneously in one photolithography step, thereby reducing fabrication process complexity while maintaining precision
Solution Approach 2:
The single mask serves multiple functions: it defines both the electrode patterns and the light emitting element patterns, acts as a barrier layer during deposition, and provides alignment references for subsequent processing steps. This multi-functional design eliminates the need for separate masks for each patterning operation
2Manufacturing precision
If multiple masks are used in the fabrication process, then manufacturing precision can be maintained, but productivity decreases
Solution Approach 1:
By merging multiple patterning operations into a single photolithography step using one mask, the patent reduces the total number of fabrication steps required. This eliminates sequential processing delays and increases overall production throughput while the precise single-step patterning maintains manufacturing quality
Solution Approach 2:
The mask is designed with pre-defined alignment features and reference patterns that enable automatic alignment systems to quickly and accurately position subsequent layers without requiring multiple iterative alignment steps, thereby speeding up the fabrication process while maintaining precision
3Use of energy by moving object
If electrode configurations are optimized for light emitting element integration, then light emission efficiency improves, but device complexity increases
Solution Approach 1:
The patent implements different electrode configurations in different regions: transparent electrodes are used in regions requiring light emission, while reflective electrodes are used in regions requiring light reflection or electrical connection. This localized optimization improves light emission efficiency without requiring complex electrode structures throughout the entire device
Solution Approach 2:
The electrode structure uses composite material layers combining transparent conductive oxides and reflective metal layers. This composite approach enables both light transmission and electrical conduction functions within a single electrode structure, improving light emission efficiency while avoiding the need for separate complex electrode systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution decreases fabrication complexity, improves light emitting element integration, and enhances light emission efficiency by optimizing electrode configurations and reducing the number of masks needed in the fabrication process.
Implementation Method 1
irradiating light onto the photoresist through the substrate by using the first electrode and the second electrode as a mask
Data Source
AI summary
A display device includes a first electrode and a second electrode disposed on a substrate and spaced apart from each other in a first direction. A light emitting element is disposed between the first electrode and the second electrode. A third electrode is disposed on the first electrode and electrically contacts an end portion of the light emitting element. A fourth electrode is disposed on the second electrode and electrically contacts another end portion of the light emitting element. A side of the third electrode and a side of the first electrode are located on a first virtual line substantially perpendicular to the substrate. A side of the fourth electrode facing the side of the third electrode and the side of the second electrode are located on a second virtual line substantially perpendicular to the substrate.