Display Electrode Layout Without Mask Patterning Steps
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Solution Overview
Problem
The existing methods for fabricating display devices are costly and complex due to the need for a mask process to pattern multiple insulating layers and electrodes, which increases the fabrication time and complexity.
Innovation Solution
A method that omits the mask process by forming a first opening in the first insulating layer to seat the light-emitting element and a second insulating layer to fix the light-emitting element and contact electrodes, reducing the number of necessary patterning steps and simplifying the fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mask process is used to pattern multiple insulating layers and electrodes, then manufacturing precision is improved, but device complexity and fabrication cost increase
Solution Approach 1:
The patent extracts and removes the mask process from the fabrication sequence by using a transfer printing method. The light-emitting element is transferred directly to the substrate with precise positioning through alignment marks, eliminating the need for multiple mask patterning steps while maintaining manufacturing precision.
Solution Approach 2:
The patent introduces a transfer substrate as an intermediary carrier. The light-emitting element is first fabricated on the transfer substrate, then transferred to the final substrate with precise positioning. This intermediary approach replaces the complex mask patterning process with a simpler transfer and alignment procedure.
2Manufacturing precision
If mask process is used to pattern multiple insulating layers and electrodes, then manufacturing precision is improved, but fabrication time is increased
Solution Approach 1:
The patent performs preliminary fabrication of the light-emitting element on a transfer substrate before final assembly. The element is pre-formed with its contacts and insulating layers, then transferred in one step to the final substrate. This preliminary action consolidates multiple sequential patterning operations into a single transfer step, significantly reducing fabrication time while maintaining precision through alignment marks.
3Manufacturing precision
If individual patterning of multiple insulating layers is performed, then manufacturing precision is improved, but fabrication cost increases
Solution Approach 1:
The patent merges multiple individual patterning operations into a single transfer printing process. The light-emitting element with its integrated insulating layers and contacts is transferred as a complete unit, eliminating the need for separate mask and etch steps for each layer. This consolidation maintains precision through alignment marks while significantly reducing fabrication cost and complexity.
Data Source
AI summary
A display device comprises a planarization layer disposed on a substrate, a first alignment electrode and a second alignment electrode that extend in a first direction and are spaced apart from each other on the planarization layer, a first insulating layer disposed on the first alignment electrode and the second alignment electrode and comprising a first opening exposing the planarization layer between the first alignment electrode and the second alignment electrode, a light-emitting element disposed on the planarization layer overlapping the first opening, a first contact electrode and a second contact electrode disposed on the first insulating layer, the first contact electrode electrically contacting a first end of the light-emitting element and the second contact electrode electrically contacting a second end of the light-emitting element, and a second insulating layer disposed on the light-emitting element.