Display Pixel Structure With Separated Reflector to Prevent Electrical Opens
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Solution Overview
Problem
The challenge with micro displays is that the bottom electrode/reflector, typically made of reactive metals like aluminum, oxidizes to form a dielectric native oxide layer during manufacturing, leading to electrical opens and poor optical performance.
Innovation Solution
The bottom electrode and reflector are designed as separate components, with a coupling structure extending from the bottom electrode to the light emission device, allowing for the use of materials that are high in reflectivity but low in oxygen reactivity, and forming conductive native oxides to prevent electrical opens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the bottom electrode/reflector is made of reactive metals like aluminum to achieve high reflectivity, then optical performance is improved, but electrical opens occur due to oxidation forming dielectric native oxide layers
Solution Approach 1:
The patent divides the bottom electrode/reflector into two separate components: a bottom electrode made of reactive metal (aluminum) for high reflectivity, and a separate reflector layer made of less reactive metal (silver or gold) that forms conductive oxide. This segmentation allows each layer to perform its specialized function without the drawbacks of using a single material.
Solution Approach 2:
The patent introduces an intermediary coupling structure between the bottom electrode and the light emission device that prevents direct contact between reactive metal and oxygen, thereby preventing dielectric oxide formation while maintaining electrical connection. This intermediary protects the electrical pathway from oxidation.
2Illumination intensity
If reactive metals are used for the bottom electrode to achieve high reflectivity, then optical performance is improved, but manufacturing yields decrease due to electrical opens
Solution Approach 1:
By segmenting the bottom electrode/reflector into separate functional layers with different material properties, the patent eliminates the manufacturing defect of dielectric oxide formation while preserving high reflectivity, thereby improving bulk manufacturing yields.
Solution Approach 2:
The patent employs a composite structure combining reactive metal (high reflectivity) with less reactive metal (conductive oxide formation), creating a system that achieves both optical performance and manufacturing reliability.
3Device complexity
If the bottom electrode and reflector are combined as a single component, then device complexity is reduced, but electrical opens occur due to oxidation
Solution Approach 1:
The patent applies segmentation by separating the bottom electrode and reflector into distinct layers, each optimized for its specific function. This increases structural complexity slightly but eliminates the harmful oxidation effect that occurs in combined structures.
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 design maintains high optical performance while preventing electrical opens, thereby improving bulk manufacturing yields and reducing manufacturing challenges.
Implementation Method 1
forming conductive native oxides to prevent electrical opens
Implementation Method 2
The bottom electrode and reflector are designed as separate components, with a coupling structure extending from the bottom electrode to the light emission device, allowing for the use of materials that are high in reflectivity
Data Source
AI summary
Various embodiments of the present disclosure are directed towards an integrated circuit (IC) chip comprising a display pixel in which a bottom electrode and a reflector are separate and border. A light emission device overlies the reflector, and a top electrode overlies the light emission device. A coupling structure extends from the bottom electrode, alongside the reflector, to an interface between the light emission device and the reflector to electrically couple the bottom electrode to the light emission device.