Display Electrode Opening Layout for Precise Light-Emitter Alignment
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Solution Overview
Problem
Current display device manufacturing processes face challenges in aligning light-emitting elements with high precision and efficiency, leading to suboptimal alignment degrees and potential defects in the display panel.
Innovation Solution
A display device design featuring a substrate with multiple electrodes and insulating layers, including openings that expose the upper surface of the electrodes, and a method involving DC voltage alignment signals to position light-emitting elements accurately, ensuring precise alignment and improved alignment degrees.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used for aligning light-emitting elements, then the manufacturing process is simpler, but the alignment degree is insufficient
Solution Approach 1:
The patent applies preliminary action by pre-forming the first insulating layer with openings that expose the upper surface of the first electrode before placing the light-emitting elements. This pre-prepared structure guides the alignment process, allowing elements to be positioned accurately through the openings without requiring complex real-time alignment mechanisms during assembly.
Solution Approach 2:
The first insulating layer with openings serves as an intermediary structure between the first electrode and the light-emitting elements. This intermediary layer provides a controlled interface that facilitates precise alignment while simplifying the overall manufacturing process, as the openings act as alignment guides without requiring additional complex alignment equipment.
2Productivity
If light-emitting elements are positioned without precise alignment control, then the manufacturing process is faster, but alignment defects occur
Solution Approach 1:
The patent implements self-service alignment where the first insulating layer with its pre-formed openings provides self-aligning features for the light-emitting elements. The openings themselves serve as alignment guides, allowing the elements to be positioned correctly through the openings without requiring external alignment equipment or complex control systems, thus maintaining high productivity while achieving precise alignment.
3Manufacturing precision
If multiple electrodes and insulating layers with openings are used, then alignment precision is improved, but device structure becomes more complex
Solution Approach 1:
The first insulating layer serves multiple functions: it provides electrical insulation between the first electrode and the light-emitting elements, and simultaneously provides alignment guidance through its pre-formed openings. This multi-functionality reduces the need for separate alignment structures, thereby improving alignment precision without proportionally increasing device complexity.
Solution Approach 2:
The patent applies local quality by creating localized openings in the first insulating layer at specific positions where alignment is needed. Rather than making the entire insulating layer complex, only the necessary local regions have openings, providing precise alignment guidance exactly where required while keeping the rest of the structure simple and functional.
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 enables improved alignment and positioning of light-emitting elements, enhancing the display device's performance and manufacturing efficiency by controlling the final positions of the elements and increasing the alignment degree.
Implementation Method 1
a first insulating layer on the first electrode, the second electrode and the third electrode and including openings exposing an upper surface of the first electrode
Implementation Method 2
a method involving DC voltage alignment signals to position light-emitting elements accurately
Data Source
AI summary
A display device includes a substrate, a first electrode, a second electrode, and a third electrode extending in a first direction on the substrate and spaced from each other, a first insulating layer on the first electrode, the second electrode, and the third electrode and including openings exposing an upper surface of the first electrode, a bank layer on the first electrode, the second electrode, the third electrode, and the first insulating layer to partition an emission area, light-emitting elements on the first electrode and the first insulating layer, and a first connection electrode in contact with one ends of the light-emitting elements and a second connection electrode in contact with opposite ends of the light-emitting elements, wherein the light-emitting elements are in contact with the upper surface of the first electrode through the openings of the first insulating layer.