LED Display Insulating Layer Trenches for Seam-Free Alignment
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Solution Overview
Problem
Display devices face challenges in preventing or reducing seams in the first insulating layer due to level differences created by electrodes, which can affect the alignment and emission efficiency of light-emitting elements.
Innovation Solution
A display device design that includes a substrate with first and second electrodes, a first insulating layer containing silicon oxynitride with specific composition ratios, and trench or protrusion portions to improve the alignment of light-emitting elements, thereby reducing seams and enhancing emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a first insulating layer is formed over electrodes with level differences, then the electrodes are insulated, but seams occur in the insulating layer due to the level differences
Solution Approach 1:
The patent applies local quality by forming protrusion portions at specific locations (first and second protrusion portions) where level differences occur between electrodes. These protrusions locally compensate for the height differences, allowing the insulating layer to maintain uniform thickness and prevent seam formation while still providing adequate insulation over the electrodes with different levels.
Solution Approach 2:
The patent implements preliminary action by pre-forming the protrusion portions in the insulating layer before final assembly or operation. This advance preparation ensures that when the insulating layer is deposited, the protrusions are already in place to compensate for electrode level differences, preventing seam formation during the insulation process.
2Manufacturing precision
If the insulating layer is made thicker to cover level differences, then seam formation is reduced, but the alignment precision of light-emitting elements deteriorates
Solution Approach 1:
Rather than uniformly increasing the insulating layer thickness, the patent uses local quality by forming protrusion portions only at specific locations where level differences exist. This localized approach provides seam prevention exactly where needed while maintaining the original thickness and alignment precision in other areas where light-emitting elements are positioned.
Solution Approach 2:
The patent segments the insulating layer structure by dividing it into flat regions and protrusion portions. The protrusion portions are segmented to specific locations (first and second protrusion portions) corresponding to different electrode levels, allowing differential thickness management that prevents seams without compromising overall alignment precision.
3Measurement precision
If protrusion portions are added to the insulating layer to improve alignment, then light-emitting element alignment improves, but the device structure becomes more complex
Solution Approach 1:
The patent applies universality by designing the protrusion portions to serve multiple functions simultaneously: they act as alignment marks for light-emitting elements, compensate for electrode level differences to prevent seams, and provide a reference plane for thickness control. This multi-functionality reduces the need for separate alignment features, thereby limiting the increase in device complexity.
Solution Approach 2:
The patent merges the alignment function with the insulation structure by integrating protrusion portions directly into the insulating layer. Instead of adding separate alignment marks or features, the protrusions are combined with the insulating layer formation process, consolidating structural and alignment functions into a single integrated feature.
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
The proposed solution effectively prevents or reduces seams in the insulating layer, improves the alignment of light-emitting elements, and enhances the emission efficiency of the display device.
Implementation Method 1
a refractive index of the first insulating layer is greater than 1.4 and less than 1.63
Implementation Method 2
the first insulating layer overlaps with the light-emitting element and comprises trench portions comprising a plurality of trenches
Data Source
AI summary
A display device includes: a substrate; a first electrode and a second electrode on the substrate, extended in a first direction and spaced apart from each other; a first insulating layer on the first electrode and the second electrode; a light-emitting element on the first insulating layer and between the first electrode and the second electrode; and a first connection electrode connected to a first end of the light-emitting element and a second connection electrode connected to a second end of the light-emitting element, wherein the first insulating layer overlaps with the light-emitting element and comprises trench portions comprising a plurality of trenches.