High-Resolution Display Pixel Electrode Patterning
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Solution Overview
Problem
Current display devices face challenges in achieving high-resolution, high-definition, and reliable manufacturing processes, particularly in forming island-shaped light-emitting layers with precise dimensions and uniform thickness, which affects the aperture ratio and manufacturing yield.
Innovation Solution
The method involves forming pixel electrodes independently for subpixels, using photolithography to create island-shaped light-emitting layers, and employing a sacrificial layer to protect the light-emitting layer during processing, along with surface treatment to improve adhesion and hydrophobicity, allowing for precise patterning and high-resolution display devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography is used to form island-shaped light-emitting layers, then manufacturing precision and resolution are improved, but device complexity and process difficulty increase
Solution Approach 1:
A sacrificial layer is formed over the light-emitting layer before photolithography processing. This preliminary action protects the light-emitting layer from damage during subsequent etching and processing steps, enabling high-precision patterning while reducing process difficulty and improving manufacturing yield.
Solution Approach 2:
The sacrificial layer acts as an intermediary protective element between the light-emitting layer and the processing environment. It shields the sensitive light-emitting material from direct exposure to etchants and mechanical stress, allowing precise pattern formation without compromising the underlying layer.
2Reliability
If surface treatment is applied to improve adhesion, then reliability is improved, but process time and complexity increase
Solution Approach 1:
Surface treatment is performed on the substrate and electrode surfaces before depositing the light-emitting layer. This preliminary hydrophobic coating enhances adhesion and prevents moisture ingress, improving device reliability without requiring additional time-consuming steps during the main fabrication process.
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 approach enables the production of display devices with high resolution, high aperture ratio, and improved reliability by reducing damage to the light-emitting layers and enhancing adhesion, resulting in clear and durable displays with increased manufacturing yield.
Implementation Method 1
forming a first sacrificial film over the first film; and forming a first layer and a first sacrificial layer to cover the pixel electrode by processing the first film and the first sacrificial film
Implementation Method 2
performing surface treatment to hydrophobize a region of the first insulating layer that is exposed from the pixel electrode
Data Source
AI summary
A high-resolution display device is provided. A pixel electrode is formed over a first insulating layer, surface treatment is performed to hydrophobize a region of the first insulating layer that is exposed from the pixel electrode, a first film including a light-emitting material is formed over the pixel electrode, a first sacrificial film is formed over the first film, a first layer and a first sacrificial layer are formed to cover the pixel electrode by processing the first film and the first sacrificial film, and the first layer is in contact with the first insulating layer in a region not overlapping with the pixel electrode.