Display Panel Insulating Layer for Cathode Adhesion Stability
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Solution Overview
Problem
During the fabrication of display panels, a gap forms due to weakened adhesion between the passivation layer (AlOx) and the diffusion layer (SWD), affecting the cathode formation and leading to disconnection defects.
Innovation Solution
The implementation of an inorganic insulating layer with strong adhesion, such as a silicon nitride (SiN) film, is introduced to enhance the bonding between the passivation layer and the diffusion layer, thereby preventing cathode disconnection defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a passivation layer formed of AlOx is used, then oxidation protection is provided, but adhesion between the passivation layer and diffusion layer weakens causing gaps
Solution Approach 1:
An inorganic insulating layer is introduced as an intermediary between the AlOx passivation layer and the diffusion layer. This intermediate layer serves as a bonding bridge that maintains both the oxidation protection function of the AlOx layer and strong adhesion to the diffusion layer, preventing gap formation while preserving protective functionality.
Solution Approach 2:
The structure employs a composite material system consisting of multiple layers with different functional properties: the AlOx passivation layer provides oxidation resistance, while the inorganic insulating layer provides strong adhesion and electrical insulation. This composite approach allows each layer to optimize its specific function while working together to solve the adhesion problem.
2Device complexity
If the adhesion between passivation layer and diffusion layer is weak, then gap formation occurs, but cathode disconnection defects are caused
Solution Approach 1:
The inorganic insulating layer acts as a mediator that mechanically bonds the passivation layer and diffusion layer together, preventing relative movement and gap formation. This intermediate bonding layer ensures stable electrical connection between the cathode and underlying structures, eliminating disconnection defects while maintaining a manageable multi-layer structure.
Solution Approach 2:
The inorganic insulating layer is deposited in advance before potential adhesion failures can occur. This preventive layer compensates for the inherently weak adhesion between AlOx and diffusion layer materials, cushioning against thermal expansion differences and mechanical stress that would otherwise cause separation and cathode disconnection.
3Reliability
If an inorganic insulating layer is added, then adhesion is improved, but manufacturing process complexity increases
Solution Approach 1:
The inorganic insulating layer is optimized with specific parameter ranges: thickness of 50-500 nm, deposition temperature of 200-400°C, and material composition (silicon nitride, silicon oxide, or silicon oxynitride). By controlling these parameters, the layer achieves strong adhesion and proper insulation while minimizing unnecessary complexity and maintaining compatibility with existing manufacturing processes.
Solution Approach 2:
The inorganic insulating layer is applied selectively in regions where adhesion enhancement is most critical, particularly at interfaces between the passivation layer and diffusion layer. This localized approach addresses the specific adhesion problem without unnecessarily complicating the entire device structure, applying the additional layer only where functional benefits are maximized.
Data Source
AI summary
A display device includes a bank pattern disposed on a substrate, a first electrode pattern disposed on the bank pattern, a light-emitting element disposed on the first electrode pattern to be electrically connected to the first electrode pattern, a second electrode pattern configured to cover the light-emitting element, an inorganic insulating layer configured to cover the bank pattern, the first electrode pattern, and the light-emitting element between the first electrode pattern and the second electrode pattern, and a diffusion layer which includes a plurality of diffusion particles and is in contact with the inorganic insulating layer.