Display Device Mask Reduction for Manufacturing Simplification
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Solution Overview
Problem
Existing display device manufacturing processes require a large number of masks, which complicates the manufacturing process and increases costs.
Innovation Solution
A display device manufacturing method that uses a reduced number of masks, involving a specific layer structure and mask process to simplify the process while maintaining effective display performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional display device manufacturing process is used, then the display device can be manufactured with standard quality, but the manufacturing process requires a large number of masks which increases process complexity and cost
Solution Approach 1:
The patent merges multiple mask functions into a single mask structure. The mask includes a first mask pattern for defining active material regions and a second mask pattern for defining electrode regions, both formed on the same mask layer. This combining of multiple patterning functions into one mask reduces the total number of masks required in the manufacturing process.
Solution Approach 2:
The mask structure is designed to perform multiple functions simultaneously. It serves as both a pattern definition tool for active materials and an alignment reference for electrodes. The mask layer acts as a universal reference structure that guides subsequent manufacturing steps, reducing the need for separate alignment marks and additional masks.
2Device complexity
If a reduced number of masks is used, then manufacturing cost and complexity are reduced, but maintaining precise alignment and patterning quality becomes more difficult
Solution Approach 1:
The mask pattern is formed in advance before the actual active material deposition and electrode formation. This preliminary mask structure serves as a permanent reference that guides all subsequent patterning steps. By establishing the alignment reference early in the process, the patent ensures that precise positioning can be maintained throughout manufacturing without requiring additional alignment masks.
Solution Approach 2:
The mask layer acts as an intermediary reference structure between the substrate and the subsequent layers. It provides a stable, pre-formed pattern that mediates the alignment between active materials and electrodes. This intermediary structure eliminates the need for direct alignment between multiple masks, thereby maintaining patterning precision with fewer masks.
Data Source
AI summary
Display device includes a first substrate; an active material layer on the first substrate and including a channel area, a first doped area on one side of the channel area, and a second doped area on another side of the channel area; a gate insulating layer on the active material layer; a first conductive layer on the gate insulating layer and including a gate electrode overlapping the channel area and a signal application electrode; a second conductive layer including a first electrode electrically connected to the first doped area, a second electrode electrically connected to the second doped area, and a third electrode electrically connected to the signal application electrode; a light emitting element; and a third conductive layer on the light emitting element, the third conductive layer including a first contact electrode electrically connected to the second electrode, and a second contact electrode electrically connected to the third electrode.