Display Electrode Insulation Structure to Prevent Layer Delamination
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Solution Overview
Problem
Display devices face issues with delamination of the insulating layer disposed on light-emitting elements, which can lead to separation and particle formation.
Innovation Solution
The display device incorporates a structure with a first and second electrode, a first and second insulating layer, and connection electrodes, featuring pattern portions and support patterns to securely fix light-emitting elements, preventing delamination during subsequent processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thin insulating layer is used on light-emitting elements, then the device structure is simplified and manufacturing is easier, but delamination occurs during subsequent processes
Solution Approach 1:
The insulating layer is segmented into multiple distinct layers: a first insulating layer directly on the light-emitting elements, a second insulating layer on the first insulating layer, and a third insulating layer on the second insulating layer. This segmentation allows each layer to perform specific functions, with the first layer providing adhesion and the subsequent layers providing protection and insulation, thereby preventing delamination while maintaining manufacturing feasibility.
Solution Approach 2:
The patent employs composite material structures where different insulating layers with distinct properties are stacked together. The first insulating layer is specifically designed to adhere to the light-emitting elements, while the second and third layers provide additional insulation and structural support. This composite approach ensures both ease of manufacture and reliability by distributing functional requirements across multiple material layers.
2Device complexity
If the insulating layer is made thinner to reduce device complexity, then manufacturing precision requirements are reduced, but delamination and particle formation occur
Solution Approach 1:
Instead of reducing the thickness of a single insulating layer, the patent adds a dimensional aspect by stacking multiple insulating layers vertically. This transforms the problem from a single-thickness-dimension challenge to a multi-layer-structure challenge, where each layer can be optimized independently for its specific function, thereby maintaining manufacturing precision while managing device complexity.
Solution Approach 2:
The insulating function is segmented across three separate layers, allowing each layer to be optimized for its specific role. The first layer focuses on adhesion to light-emitting elements, the second layer provides intermediate insulation, and the third layer provides final protection. This segmentation eliminates the need for a single thick layer, reducing overall device complexity while maintaining manufacturing precision.
3Device complexity
If a single insulating layer is used, then the structure is simpler, but delamination occurs during subsequent processes
Solution Approach 1:
The single insulating layer is segmented into three distinct layers with different functions. The first insulating layer is specifically designed to adhere to the light-emitting elements, preventing delamination. The second and third layers provide additional insulation and protection. This segmentation maintains reliability while keeping the overall structure relatively simple through a systematic multi-layer approach.
Solution Approach 2:
The patent uses composite material structures where three different insulating layers are stacked together, each with optimized properties for its specific function. This composite approach ensures reliability by distributing mechanical and electrical stresses across multiple layers, preventing delamination that would occur in a single-layer structure, while maintaining manageable device complexity.
Data Source
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AI summary
Disclosed is a display device. The display device comprises: a light emitting region; a sub region spaced apart from the light emitting region in a first direction; a first electrode extending in the first direction; a second electrode spaced apart from the first electrode and extending in the first direction; a first insulating layer disposed on the first electrode and the second electrode; light emitting elements having at least one end disposed on the first electrode or the second electrode; a second insulating layer including a first pattern part, which is disposed on the light emitting elements and extends in the first direction, and a first base part disposed in the sub region; a first connection electrode disposed on the first electrode and in contact with the light emitting element; and a second connection electrode disposed on the second electrode and in contact with the light emitting element, wherein the first pattern part spans the sub region and the light emitting region and is connected to the first base part.