Inorganic LED Display Electrode Layout for Single-Mask Patterning
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Solution Overview
Problem
The manufacturing process for inorganic light emitting diodes is complex and requires multiple masks, limiting efficiency and durability compared to organic light emitting diodes.
Innovation Solution
A display device and method involving nano-scale to micro-scale light emitting elements with reduced mask usage, featuring a pixel circuit layer, partition walls, electrodes, and a semiconductor pattern that connects the light emitting element upon voltage application, with an insulating layer and contact electrodes for improved electrical stability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional inorganic light emitting diode manufacturing process is used, then the durability and blue light efficiency are improved, but the manufacturing complexity increases due to multiple masks being required
Solution Approach 1:
The patent combines multiple mask functions into a single mask structure that defines both the light emitting element pattern and the contact electrode pattern simultaneously. This merging of patterning functions reduces the total number of masks from multiple separate masks to one integrated mask, simplifying the manufacturing process while maintaining the durability and efficiency benefits of inorganic LEDs
2Manufacturing precision
If multiple masks are used in the manufacturing process, then precise patterning is achieved, but the productivity decreases due to increased process steps
Solution Approach 1:
The single mask design integrates multiple patterning functions into one structure, allowing simultaneous definition of light emitting elements and contact electrodes. This reduces the number of sequential patterning steps while maintaining precise positioning through the integrated mask design, thereby improving manufacturing efficiency without sacrificing patterning precision
Solution Approach 2:
The mask is designed with pre-configured opening patterns that anticipate both the light emitting element positions and contact electrode positions. This preliminary design of the mask structure enables both features to be patterned in a single step, eliminating the need for subsequent patterning operations and streamlining the manufacturing process
3Productivity
If the number of masks is reduced, then the manufacturing process is simplified and productivity is improved, but the manufacturing precision may be compromised
Solution Approach 1:
The integrated mask combines multiple patterning functions into a single structure with precisely positioned openings for both light emitting elements and contact electrodes. This merging maintains high manufacturing precision because all critical dimensions and positions are defined in one mask fabrication process, eliminating alignment errors that would accumulate across multiple separate masking steps
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 simplifies the manufacturing process, enhances the durability and efficiency of inorganic light emitting diodes by reducing the number of masks needed, leading to improved light emitting performance and stability.
Implementation Method 1
a transfer method using a dielectrophoresis (DEP) method has been developed
Data Source
AI summary
A display device includes: a pixel circuit layer including a plurality of transistors; first partition wall and a second partition wall on the pixel circuit layer, each of the first and second partition walls having a shape protruding in a thickness direction; a first electrode and a second electrode on the same layer and respectively on the first partition wall and the second partition wall; a light emitting element between the first electrode and the second electrode; and a semiconductor pattern directly on the first electrode.