Display Pixel Electrode Layout for Reliable LED Connections
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Solution Overview
Problem
Existing display device manufacturing processes are complex and prone to variations due to the need for multiple mask processes to connect light emitting elements to electrodes, which can lead to unreliable connections.
Innovation Solution
A simplified manufacturing process for display devices involving the formation of insulating patterns that protrude beyond the electrodes, allowing for direct contact electrode formation on the light emitting elements, reducing the number of mask processes and enhancing reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mask processes are used to connect light emitting elements to electrodes, then the connections can be formed, but the manufacturing process becomes complex and prone to variations
Solution Approach 1:
The insulating patterns are formed to protrude beyond the electrodes in advance, creating predetermined contact portions that will later receive contact electrodes. This preliminary structuring eliminates the need for multiple mask processes during subsequent connection formation, as the contact portions are already positioned and sized correctly to receive the light emitting elements and form reliable connections.
2Manufacturing precision
If multiple mask processes are used to form connections, then electrode connections can be established, but process variations increase
Solution Approach 1:
The insulating patterns are pre-formed with protruding contact portions that define the exact location and dimensions for electrode connections. This preliminary action establishes precise alignment references before light emitting elements are mounted, ensuring consistent connection positioning and reducing variability in connection precision across different manufacturing batches.
Solution Approach 2:
The insulating patterns themselves serve dual functions: they provide electrical insulation for the electrodes and simultaneously create the contact portions that guide and support the light emitting elements. This self-service structure eliminates the need for separate alignment and connection structures, reducing the number of process steps and minimizing cumulative process variations.
3Ease of manufacture
If insulating patterns protrude beyond electrodes, then direct contact electrode formation is enabled, but the insulating pattern structure becomes more complex
Solution Approach 1:
The insulating patterns are designed to perform multiple functions simultaneously: providing electrical insulation for the electrodes, creating protruding contact portions for light emitting element mounting, and serving as alignment references for subsequent electrode formation. By merging these functions into a single structural element, the overall manufacturing process is simplified even though the insulating pattern geometry becomes more elaborate.
Data Source
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AI summary
A display device includes a pixel in a display area. The pixel includes a first electrode and a second electrode spaced from each other; a first insulating pattern on the first electrode, the first insulating pattern protruding to an outside of the first electrode while having a width greater than that of the first electrode; a second insulating pattern on the second electrode, the second insulating pattern protruding to an outside of the second electrode while having a width greater than that of the second electrode; a light emitting element arranged between the first insulating pattern and the second insulating pattern, the light emitting element including a first end and a second end; a third insulating pattern on a portion of the light emitting element to expose the first end and the second end of the light emitting element; and a first contact electrode on the light emitting element.