Display Device Manufacturing via Sacrificial Film Patterning
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Solution Overview
Problem
Existing display devices face challenges in achieving high resolution, high display quality, high contrast, high color reproducibility, and high aperture ratio, with conventional manufacturing methods struggling to produce reliable and efficient displays.
Innovation Solution
A manufacturing method for display devices involving the formation of separate EL layers between pixel electrodes using sacrificial films and insulating layers, allowing for precise patterning without shadow masks, and employing heat treatment and etching processes to create a novel structure with improved yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used, then the display device can be manufactured with existing processes, but the resolution and display quality are limited
Solution Approach 1:
The manufacturing process is divided into multiple sequential steps: forming first and second EL films with different light-emitting materials, depositing first and second sacrificial films, selectively removing portions, and forming first and second insulating layers. This segmentation allows precise patterning of separate EL layers between pixel electrodes, achieving high resolution without requiring complex shadow mask techniques.
Solution Approach 2:
Sacrificial films are deposited over the EL films before selective removal. These sacrificial films serve as temporary structures that enable precise control during the formation of insulating layers and pixel electrodes. The preliminary deposition of sacrificial films allows subsequent selective removal to create precise gaps and patterns, achieving high manufacturing precision through staged processes.
2Manufacturing precision
If separate EL layers are formed between pixel electrodes, then the aperture ratio and display quality improve, but the manufacturing process becomes more complex
Solution Approach 1:
Insulating layers are formed between the first and second EL films to electrically isolate them while maintaining their spatial arrangement. These insulating layers act as intermediaries that enable the formation of separate EL layers between pixel electrodes without requiring complex direct patterning. The insulating layers simplify the overall structure by providing clear electrical separation while maintaining the high aperture ratio through precise spatial positioning.
3Manufacturing precision
If multiple films and layers are formed and removed, then the resolution and contrast improve, but the manufacturing time increases
Solution Approach 1:
Multiple functions are combined into single steps where possible. For example, the sacrificial films serve both as pattern-defining structures and as barriers during film formation. The insulating layers simultaneously provide electrical isolation and structural support. This merging of functions reduces the number of discrete operations needed, decreasing manufacturing cycle time while maintaining high contrast through precise EL layer separation.
Data Source
AI summary
A display device with high resolution is provided. A first insulating layer covering an end portion of a pixel electrode is formed; a first layer overlapping with part of the first insulating layer and a first pixel electrode is formed and another part of the first insulating layer and a second pixel electrode are exposed; a second layer overlapping with the another part of the first insulating layer and the second pixel electrode is formed; a second insulating layer covering the first insulating layer is formed; a resin layer overlapping with the first insulating layer is formed over the second insulating layer; and a common electrode is formed to cover the first film, the second film, and the resin layer. The first film contains a first light-emitting material that emits first light, and the second film contains a second light-emitting material that emits second light of a color different from that of the first light.