Display Electrode Layout With Insulating Bank to Prevent Step Differences
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Solution Overview
Problem
The existing display devices face issues with step differences in common electrodes due to light emitting elements being disposed outside emission areas, leading to potential disconnection and reduced reliability.
Innovation Solution
A display device design where light emitting elements are only disposed in emission areas by removing those outside, using a bank structure with an insulating layer and a via layer to ensure proper electrode contact and prevent step differences, and a method of manufacturing involving photoresist patterns and selective removal of non-emitting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light emitting elements are disposed in areas other than emission areas, then the manufacturing process is simplified, but step differences occur in the common electrode causing disconnection and reduced reliability
Solution Approach 1:
The patent removes light emitting elements that are disposed in areas other than emission areas. This extraction eliminates the harmful effect of these misplaced elements causing step differences in the common electrode, while preserving the simplified manufacturing process that initially placed them there.
Solution Approach 2:
The patent introduces an insulating layer as an intermediary structure between the substrate and the common electrode. This insulating layer fills the areas where light emitting elements were removed, preventing step differences and ensuring the common electrode remains connected without requiring complex repositioning of the light emitting elements.
2Reliability
If light emitting elements are removed from non-emission areas, then common electrode reliability is improved, but additional manufacturing steps are required
Solution Approach 1:
The patent performs the removal of light emitting elements from non-emission areas as a preliminary step before forming the common electrode. This preliminary action prevents the formation of step differences that would otherwise complicate subsequent manufacturing steps, thereby improving reliability without significantly increasing overall process complexity.
Solution Approach 2:
The insulating layer serves as an intermediary that simplifies the manufacturing process by filling the gaps where light emitting elements were removed. This eliminates the need for complex repositioning or adjustment steps, maintaining manufacturing simplicity while ensuring common electrode reliability.
3Manufacturing precision
If light emitting elements are disposed only in emission areas, then step differences are prevented in the common electrode, but the manufacturing process requires selective removal steps
Solution Approach 1:
The patent selectively removes light emitting elements from non-emission areas using a straightforward extraction process. This achieves precise positioning of light emitting elements only in emission areas without requiring complex repositioning or adjustment mechanisms, thereby maintaining manufacturing precision with relatively simple process steps.
Solution Approach 2:
The insulating layer acts as an intermediary that fills the spaces where light emitting elements were removed, enabling precise positioning without requiring complex control mechanisms during the placement process. This simplifies the manufacturing process while achieving the desired precision in light emitting element positioning.
Data Source
AI summary
According to an embodiment of the disclosure, a display device may include a first electrode disposed on a substrate, a bank disposed on the substrate and including an opening exposing at least a portion of the first electrode, light emitting elements disposed on the first electrode, an insulating layer disposed on the bank to overlap the bank in a plan view, and a second electrode disposed on the insulating layer and the light emitting elements.