Display device and method of manufacturing the same
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Solution Overview
Problem
Current display device manufacturing processes are costly and inefficient, particularly in forming transparent conductive polymer components like contact electrodes and bank patterns, which are crucial for light emission directionality and electrical connectivity.
Innovation Solution
The use of a transparent conductive polymer layer, including materials like PEDOT:PSS, polyacetylene, and polypyrrole, is etched using a photoresist mask with varying transmissivity areas to simultaneously form contact electrodes and bank patterns, reducing the number of processing steps and masks required, thereby lowering production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate processes are used to form contact electrodes and bank patterns, then manufacturing precision can be maintained, but processing cost and device complexity increase
Solution Approach 1:
The patent merges the formation of contact electrodes and bank patterns into a single etching process. A transparent conductive polymer layer is deposited across the entire substrate, then patterned using one photolithography and etching step to create both the contact electrodes (in open areas) and the bank patterns (in patterned areas) simultaneously. This eliminates the need for separate deposition and etching steps for each component, reducing processing cost and simplifying the manufacturing workflow.
Solution Approach 2:
The transparent conductive polymer layer serves multiple functions: it acts as the material source for both contact electrodes and bank patterns. By using a single universal material layer that can be differentially processed through photolithography masking, the patent achieves multi-functionality where one layer fulfills the roles of multiple separate components, thereby reducing the number of processing steps and masks required.
2Productivity
If a single etching process is used to form both contact electrodes and bank patterns, then productivity increases, but manufacturing precision may be compromised
Solution Approach 1:
The patent applies local quality by using photolithography masks with different transmissivity characteristics in different regions of the substrate. Areas requiring contact electrodes receive masks with higher transmissivity allowing complete etching, while areas requiring bank patterns receive masks with lower transmissivity allowing partial etching. This enables precise local control of etching depth and pattern formation within a single etching process, maintaining manufacturing precision while improving productivity.
Solution Approach 2:
The patent utilizes parameter changes in the photolithography process, specifically varying the transmissivity of masks across different regions. By adjusting mask transmissivity parameters, the etching process can be controlled to produce different pattern types (contact electrodes vs. bank patterns) from the same transparent conductive polymer layer, ensuring precise pattern formation while maintaining high manufacturing efficiency.
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 method enables the cost-effective manufacturing of display devices with improved light emission efficiency and reduced processing complexity by integrating the formation of contact electrodes and bank patterns into a single etching process, enhancing the display device's performance and manufacturing efficiency.
Implementation Method 1
disposing a photoresist layer including photosensitive material on the transparent conductive polymer layer, removing at least part of the photoresist layer using a mask
Implementation Method 2
etching the transparent conductive polymer layer using an etching mask, wherein the etching mask is the photoresist layer of which the at least part is removed
Data Source
AI summary
A display device may include a substrate, and a display element layer disposed on the substrate and including a light emitting element that emits light in a display direction. The display element layer may include a first contact electrode electrically connected to the light emitting element, a second contact electrode electrically connected to the light emitting element, and a bank pattern having a shape extending in the display direction. At least one of the first contact electrode, the second contact electrode, and the bank pattern may include a transparent conductive polymer.