Pixel Electrode Layout With Shared Mask Patterning in Display Panels
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Solution Overview
Problem
Existing display device manufacturing processes require multiple masks, increasing production costs.
Innovation Solution
A display device design that reduces the number of masks by using a first insulating layer with a residual bank pattern and a second insulating layer with wider openings, allowing for the electrodes of adjacent pixels to be spaced apart, and a method of manufacturing that includes patterning a photoresist layer to etch electrodes without additional masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the manufacturing process to pattern insulating layers and electrodes, then manufacturing precision is improved, but device complexity and production cost increase
Solution Approach 1:
The patent merges the patterning functions of multiple masks into a single mask by designing the mask to define both the first insulating layer pattern and the electrode pattern simultaneously. This is achieved by configuring the mask with different transparent and opaque regions that correspond to different pattern requirements, allowing both layers to be patterned in one step without requiring separate masking operations.
Solution Approach 2:
The single mask serves multiple functions by simultaneously defining the patterns for both the first insulating layer and the electrodes. The mask is designed with regions that perform different patterning functions - some regions define the insulating layer boundaries while other regions define the electrode positions, making the mask a multi-functional tool that replaces what would traditionally require multiple specialized masks.
2Manufacturing precision
If additional masks are used to pattern electrodes after forming insulating layers, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The mask is designed in advance with pre-configured transparent and opaque regions that anticipate the need to pattern both the first insulating layer and the electrodes. By preparing the mask with all necessary pattern definitions before the manufacturing process begins, the patent eliminates the need for subsequent repatterning steps, allowing both layers to be formed in a single coordinated operation that improves throughput.
Solution Approach 2:
The patent combines the patterning operations for the first insulating layer and the electrodes into a single simultaneous process step. The mask enables both patterns to be defined and formed in one exposure and development cycle, eliminating sequential operations and thereby significantly improving manufacturing efficiency without sacrificing the precision needed for electrode positioning.
3Manufacturing precision
If the number of manufacturing steps is increased to achieve precise electrode spacing, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The mask is segmented into distinct functional regions with different optical properties - transparent regions that allow pattern formation in underlying layers and opaque regions that prevent pattern formation. This segmentation enables the mask to simultaneously define precise spacing for electrodes while forming the first insulating layer, achieving accurate electrode positioning without requiring additional time-consuming measurement and adjustment steps.
Solution Approach 2:
The precise electrode spacing is built into the mask design from the beginning, with transparent and opaque regions positioned to automatically ensure correct spacing when the patterning is performed. This preliminary configuration of spacing parameters in the mask eliminates the need for subsequent time-consuming adjustments or verification steps, achieving precise electrode spacing in a single operation.
Data Source
AI summary
A display device includes pixels. Each of the pixels includes electrodes disposed on a base layer; a first insulating layer disposed on the electrodes; a light emitting element disposed on the first insulating layer; a bank disposed on the first insulating layer and protruding in a thickness direction of the base layer; and a second insulating layer, at least a portion of the second insulating layer being disposed on the first insulating layer. At least part of the electrodes of a pixel among the pixels are spaced apart from at least part of the electrodes of another pixel adjacent to the pixel with an open area being disposed between the electrodes. The first insulating layer includes a first opening overlapping the open area in a plan view, and the second insulating layer includes a second opening overlapping the open area in a plan view.