Light-Emitting Display Electrode Layout With Fewer Mask Steps
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Solution Overview
Problem
The existing manufacturing processes for display devices with light emitting elements require multiple masks, which complicates the process and increases costs.
Innovation Solution
A method of manufacturing a display device that reduces the number of masks used by aligning light emitting elements between electrodes and forming organic patterns directly on the light emitting elements, along with contact electrodes, using a multi-layer organic material process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the existing manufacturing process, then the light emitting elements can be manufactured with proper alignment, but the manufacturing process becomes complex and costs increase
Solution Approach 1:
The patent combines multiple mask alignment steps into a single maskless alignment process by using direct optical alignment between the light emitting element and electrode patterns. This merging of steps eliminates the need for multiple masks while maintaining alignment precision, directly resolving the contradiction between manufacturing precision and process complexity
Solution Approach 2:
The patent extracts and eliminates the mask components from the manufacturing process entirely. By removing the masks and replacing them with a maskless alignment method using optical fields, the process complexity is reduced while the essential alignment function is preserved through direct optical alignment between components
2Manufacturing precision
If multiple masks are used in the existing manufacturing process, then the light emitting elements can be manufactured with proper alignment, but manufacturing costs increase
Solution Approach 1:
The patent extracts and removes the expensive mask components from the manufacturing process. By eliminating masks and their associated alignment steps, direct optical alignment is used instead, which reduces material costs and process complexity while maintaining the required alignment precision for light emitting elements
Solution Approach 2:
The patent replaces expensive, reusable masks with a maskless approach that uses temporary optical alignment fields during the manufacturing process. This substitution eliminates the need for costly mask materials and their maintenance, reducing overall manufacturing costs while achieving the same alignment precision
3Device complexity
If organic patterns are formed directly on light emitting elements without masks, then the manufacturing process is simplified, but the surface flatness becomes a challenge
Solution Approach 1:
The patent performs preliminary planarization by forming an organic layer that fills the spaces between protruding partition walls before forming the final organic patterns. This preliminary action creates a flat base surface, enabling subsequent maskless patterning while maintaining the required surface flatness for display device performance
Solution Approach 2:
The patent applies different organic materials with different properties to different locations: a planarization organic layer is applied in areas requiring flatness (between partition walls), while pattern-forming organic materials are applied where precise patterning is needed. This local differentiation resolves the contradiction between process simplification and surface flatness
Data Source
AI summary
A display device and a manufacturing method thereof are disclosed. The display device may include a pixel circuit layer including a plurality of transistors, a first partition wall and a second partition wall on the pixel circuit layer, and each protruding in a thickness direction, a first electrode and a second electrode formed on the same layer, and on the first partition wall and the second partition wall, respectively; a light emitting element between the first electrode and the second electrode; and a first organic pattern directly on the light emitting element.