Display Pixel Electrode Layout for Fewer Mask Alignment Steps
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Solution Overview
Problem
The existing manufacturing processes for display devices are complex and require multiple masks, making them inefficient and costly.
Innovation Solution
A simplified manufacturing process for display devices is developed, which uses fewer masks by stabilizing light emitting elements with contact electrodes and insulating patterns, allowing for the omission of separate fixing components and utilizing insulating patterns as etching masks to connect pixel circuit portions with display elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the manufacturing process, then the light emitting elements can be precisely positioned and fixed, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent combines the positioning and fixing functions into a single integrated structure where the insulating pattern serves both as a positioning guide and as a fixing component. The contact electrodes are formed to extend along the long sides of the light emitting elements, merging the electrical connection function with the mechanical support function, thereby eliminating the need for separate positioning masks and fixing structures.
Solution Approach 2:
The insulating pattern is designed to perform multiple functions simultaneously: it provides electrical insulation, serves as a positioning reference for light emitting element placement, and acts as a mechanical support structure. The etching masks are also designed to serve dual purposes - defining the insulating pattern geometry while simultaneously creating the contact electrode structures, reducing the total number of manufacturing steps.
2Reliability
If separate fixing components are used to stabilize light emitting elements, then the elements are securely fixed, but the manufacturing process requires additional masks and steps
Solution Approach 1:
The patent merges the fixing function with the insulating pattern and contact electrode structure. The insulating pattern extends beyond the short sides of the light emitting elements to provide mechanical support and positioning, while the contact electrodes extend along the long sides to provide both electrical connection and structural support, eliminating the need for separate fixing components.
Solution Approach 2:
The insulating pattern and contact electrodes are designed to self-align and self-fix the light emitting elements during the manufacturing process. The geometric configuration of these structures automatically provides positioning and fixation without requiring additional alignment steps or separate fixing operations, thereby simplifying the manufacturing process.
3Ease of manufacture
If insulating patterns are used as etching masks, then the manufacturing process is simplified, but the patterns must serve dual functions
Solution Approach 1:
The insulating patterns are designed with multi-functionality from the outset, serving as both the etching mask definition and the final functional component providing insulation, positioning, and structural support. The contact electrodes are similarly designed to serve both as the etching mask pattern and as the final electrical connection structure, thereby simplifying the manufacturing process while managing functional complexity through careful design integration.
Data Source
AI summary
A display device includes: a substrate having a display area and a non-display area; and a pixel in each of a pixel area in the display area. Each of the pixels includes: an insulating layer on the substrate and having an opening; first and second electrodes on the insulating layer and spaced apart from each other; a plurality of light emitting elements in the opening; a first contact electrode electrically connecting one end of the light emitting elements and the first electrode to each other; a second contact electrode electrically connecting another end of the light emitting elements and the second electrode to each other; a first insulating pattern on the first contact electrode; and a second insulating pattern on the second contact electrode. The first insulating pattern and the second insulating pattern are on the same layer and spaced apart from each other.