Display Panel Electrode Insulation and Maskless Manufacturing
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Solution Overview
Problem
Existing display panel manufacturing methods face challenges in preventing short circuits and ensuring reliability due to the diffusion of impurities and crosstalk between light-emitting devices, leading to display defects and unevenness.
Innovation Solution
A display panel design incorporating a first and second light-emitting device with specific electrode configurations, insulating films, and a conductive film to prevent short circuits and impurity diffusion, while using a method that avoids the use of metal masks for manufacturing, allowing for the formation of light-emitting devices without fine metal masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fine metal mask is used to form light-emitting layers, then manufacturing precision can be improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and removes the fine metal mask from the manufacturing process. Instead of using a metal mask to define the light-emitting layer patterns, the invention forms continuous light-emitting layers that cross the display region and uses subsequent processing steps to create the desired patterns, thereby eliminating the complexity and cost associated with fine metal masks while maintaining manufacturing precision
Solution Approach 2:
The patent inverts the conventional approach by first forming continuous light-emitting layers without masks and then using insulating films with openings to define the active regions. This reverse methodology achieves the same patterning function but eliminates the need for fine metal masks, reducing device complexity while preserving manufacturing precision
2Reliability
If insulating films and conductive films are added to prevent short circuits, then reliability can be improved, but device complexity increases
Solution Approach 1:
The insulating film serves multiple functions simultaneously: it provides electrical insulation to prevent short circuits between adjacent electrodes, defines the boundaries of light-emitting regions through its openings, and acts as a structural support layer. This multi-functionality improves reliability while minimizing the increase in device complexity by consolidating multiple roles into a single film layer
Solution Approach 2:
The conductive film acts as an intermediary element that electrically connects the second electrode to the fourth electrode through openings in the insulating film. This mediator structure prevents short circuits by providing controlled electrical pathways while maintaining proper electrical isolation in other regions, thereby improving reliability without significantly increasing overall device complexity
Data Source
AI summary
A novel display panel that is highly convenient, useful, or reliable can be provided. The display panel includes a first light-emitting device, a second light-emitting device, a first insulating film, and a conductive film. The first light-emitting device includes a first electrode and a second electrode; the first electrode includes a first region overlapping with the second electrode and a second region outside the first region. The second light-emitting device includes a third electrode and a fourth electrode, and the third electrode includes a third region overlapping with the fourth electrode and a fourth region outside the third region. The first insulating film is in contact with the second region and the fourth region, and the first insulating film includes a first opening and a second opening. The first opening overlaps with the second electrode and the second opening overlaps with the fourth electrode. The conductive film is electrically connected to the second electrode and the fourth electrode in the first opening and in the second opening, respectively.