Display Device Insulating Layer Overlap for Short-Circuit Prevention
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Solution Overview
Problem
Display devices face challenges in preventing short-circuit failures in electrodes and simplifying the manufacturing process, particularly in the integration of light-emitting elements and insulating layers.
Innovation Solution
A display device design that includes electrodes spaced apart with insulating layers and organic patterns, where the insulating pattern overlaps the light-emitting element, exposing its ends and allowing for the formation of connection electrodes on the same layer, simplifying the manufacturing process by reducing the number of masks required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulating layers and openings are used to prevent short-circuit failures, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple insulating layers (first insulating layer and second insulating layer) and their respective openings (first opening and second opening) into a unified insulating structure. The openings are positioned to overlap in plan view, creating a consolidated pathway that reduces the number of separate insulating structures needed while maintaining short-circuit prevention functionality.
Solution Approach 2:
The patent utilizes the vertical dimension by stacking insulating layers and openings in different layers. The first opening in the first insulating layer and the second opening in the second insulating layer are offset from each other in plan view but overlap when viewed from above, effectively using three-dimensional space to simplify the overall structure.
2Manufacturing precision
If multiple masks are used for precise formation of insulating patterns and connection electrodes, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent merges the formation of insulating patterns and connection electrodes into a single manufacturing step. The insulating pattern and connection electrodes are formed simultaneously in the same opening, eliminating the need for separate masking and formation steps for each component, thereby improving productivity while maintaining precision.
3Reliability
If connection electrodes are formed on different layers, then reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent transitions from a vertical stacking approach to a planar arrangement by forming both connection electrodes on the same layer. The electrodes are positioned at opposite ends of the light-emitting element within the same insulating opening, utilizing horizontal separation rather than vertical layering, which simplifies the device structure while maintaining electrical isolation.
Data Source
AI summary
Provided herein is a display device and a method of manufacturing the same. The display device includes electrodes spaced apart from each other, a first insulating layer disposed on the electrodes and including a first opening, a light-emitting element disposed on the first insulating layer and disposed between adjacent ones of the electrodes, and organic patterns disposed between adjacent ones of the electrodes in the first opening.