Display Electrode Layout Using Self-Aligned Mask Patterning
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Solution Overview
Problem
Existing display device fabrication processes require multiple masks, increasing complexity and cost, and there is a need for a more efficient method to reduce the number of masks used.
Innovation Solution
A display device is fabricated with a method that involves forming a first and second electrode on a substrate, aligning a light emitting element between them, using these electrodes as a mask for photoresist irradiation, and then etching to form third and fourth electrodes, all while minimizing opaque conductive material between the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the fabrication process, then the fabrication precision and electrode alignment are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple mask functions into a single mask structure. The mask includes a first mask portion for forming the first electrode and a second mask portion for forming the second electrode, allowing both electrodes to be formed in one photolithography step rather than requiring separate masks for each electrode, thereby reducing the total number of masks while maintaining alignment precision
Solution Approach 2:
The single mask structure serves multiple functions: it defines the pattern for the first electrode, defines the pattern for the second electrode, and establishes the spacing between them. This multi-functional mask replaces what would traditionally require multiple specialized masks, reducing complexity while maintaining manufacturing precision
2Manufacturing precision
If multiple masks are used in the fabrication process, then the electrode pattern accuracy is improved, but the production cost increases
Solution Approach 1:
By merging the patterning functions for both electrodes into a single mask and single photolithography step, the patent reduces the number of expensive mask materials, alignment procedures, and processing steps required, thereby lowering production cost while maintaining electrode pattern accuracy through the integrated mask design
Solution Approach 2:
The mask is designed in advance with both the first and second electrode patterns pre-defined in specific regions. This preliminary configuration allows both electrodes to be formed simultaneously with accurate relative positioning in one step, eliminating the need for subsequent alignment operations and reducing manufacturing cost
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
This approach reduces the number of masks required, simplifying the fabrication process and potentially lowering production costs while maintaining electrical connectivity and structural integrity.
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.