Display Device Protrusion Patterns Planarization
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Solution Overview
Problem
Display devices with corner cutout portions and protrusion patterns face challenges in stably forming thin films and touch panels due to the complexity of planarization and insulation layers, leading to reliability issues.
Innovation Solution
A display device design featuring a substrate with protrusion patterns and cutout portions, where a planarization layer is formed on the protrusion patterns and cutout portions, and a sacrificial layer is used to create a stable thin film and touch panel structure, with specific insulation and touch electrode configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If protrusion patterns and cutout portions are added to the substrate to enable display on bent surfaces, then adaptability and display area are improved, but manufacturing precision and reliability of thin film formation deteriorate
Solution Approach 1:
A planarization layer is formed in advance on the substrate before forming the thin film, to preliminarily flatten the surface irregularities caused by protrusion patterns and cutout portions. This preliminary planarization enables subsequent thin film formation to proceed with high precision despite the complex substrate geometry.
Solution Approach 2:
The planarization layer is selectively formed in regions where protrusion patterns and cutout portions create surface irregularities, providing local planarization only where needed. This allows the thin film to be formed with high precision on critical areas while maintaining the overall three-dimensional structure for adaptability.
2Reliability
If multiple insulation layers and planarization layers are added to ensure stable thin film formation, then reliability is improved, but device complexity increases
Solution Approach 1:
The insulation structure is segmented into multiple functional layers: a first insulation layer that provides base insulation and a second insulation layer that provides additional insulation and planarization. This segmentation allows each layer to perform its specific function optimally, ensuring reliable thin film formation while keeping the overall structure organized and manageable.
Solution Approach 2:
The planarization layer serves multiple functions simultaneously: it provides electrical insulation, creates a planar surface for thin film deposition, and structurally supports the protrusion patterns and cutout portions. This multi-functionality reduces the need for separate dedicated layers, thereby managing device complexity while maintaining reliability.
3Reliability
If the first insulation layer covers side surfaces of display layer on protrusion patterns, then insulation reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The first insulation layer is extended from covering only the top surface of the display layer to also covering the side surfaces. This dimensional extension into the vertical dimension ensures complete insulation coverage on protrusion patterns, preventing electrical breakdown while maintaining a relatively simple single-layer structure.
Data Source
AI summary
A display device and a method of manufacturing the display device are provided. Embodiments of the display device include a substrate including a main portion and a plurality of protrusion patterns protruding outwardly from an edge of the main portion, a display layer on each of the protrusion patterns, a first insulating layer covering the display layer and a second insulating layer on the first insulating layer. Adjacent protrusion patterns are separated by a cutout portion and side surfaces of the adjacent protrusion patterns face each other. The first insulating layer includes adjacent first insulating layers on the adjacent protrusion patterns that face each other and are separated by the cutout portion. The second insulating layer is on a top surface of the first insulating layer on each of the protrusion patterns, and is not on a side surface of the display layer.