Display Device Pixel Defining Layer Spacer Integration
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Solution Overview
Problem
The existing flat panel display devices face challenges in improving productivity and display quality due to differences in materials between pixel defining layers and spacers, which complicates the manufacturing process and affects critical dimension distribution.
Innovation Solution
The display device incorporates a planarization layer with a first flat portion and a protrusion, along with a bank portion and spacer portion made from the same negative photosensitive material, including black pigment, to enhance the critical dimension distribution of the pixel defining layer using a halftone mask in the photolithography process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pixel defining layer and spacer are made from different materials, then display quality can be improved, but the number of masks and process steps must be increased
Solution Approach 1:
The pixel defining layer and spacer are merged into a single integrated structure formed from the same negative photosensitive material through a single photolithography process, eliminating the need for separate manufacturing steps while maintaining the functional distinction between the two components
Solution Approach 2:
The negative photosensitive material serves dual functions by forming both the pixel defining layer and the spacer through a single coating and exposure process, allowing one material to perform multiple structural roles in the display device
2Reliability
If pixel defining layer and spacer are made from different materials, then functional performance can be optimized, but productivity decreases due to additional process steps
Solution Approach 1:
The pixel defining layer and spacer are combined into a single component formed from the same negative photosensitive material through one photolithography process, reducing the total number of manufacturing steps and improving production efficiency while maintaining functional performance
Solution Approach 2:
The negative photosensitive material is pre-configured with properties that enable it to form both the pixel defining layer and spacer structures in a single exposure process, allowing both functional elements to be created simultaneously before other manufacturing steps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration improves the critical dimension distribution of the pixel defining layer, simplifying the manufacturing process and enhancing display quality by allowing for more precise control during the photolithography process.
Implementation Method 1
a pixel defining layer disposed on the planarization layer. In such an embodiment, the pixel defining layer includes a bank portion, in which an opening is defined to expose a portion of the pixel electrode, and a spacer portion protruding in the thickness direction from an upper surface of the bank portion
Data Source
AI summary
A display device includes a substrate including a display area and a peripheral area, a driving element disposed in the display area on the substrate, a pixel electrode disposed on the driving element and connected to the driving element, a planarization layer including a first flat portion covering the driving element on the driving element and a first protrusion portion protruding in a thickness direction from an upper surface of the first flat portion adjacent to the pixel electrode, and a pixel defining layer disposed on the planarization layer. The pixel defining layer includes a bank portion, in which an opening is defined to expose a portion of the pixel electrode; and a spacer portion protruding in the thickness direction from an upper surface of the bank portion and spaced apart from the first protrusion portion in a plan view.