Electrode Side Face Insulation for Leak Current Suppression
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Solution Overview
Problem
Conventional electroluminescent devices face issues with leak current flowing through the side faces of electrodes, leading to nonuniform light emission, reduced reliability, and potential short-circuiting due to thin light emitting layer regions, and existing solutions complicate the production process and reduce efficiency.
Innovation Solution
A base plate with electrodes is developed, where side face regions are imparted with electrical insulation characteristics using a simple process involving the formation of electrical insulating sections at electrode gaps or through composition alteration with processing gases, ensuring high open face rates and reliable insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a black matrix is formed to cover side faces of electrodes, then leak current is suppressed, but the number of processing steps increases and production efficiency decreases
Solution Approach 1:
The patent combines the electrode formation and insulation formation into a single integrated process. The insulation layers are formed simultaneously with the electrode pattern formation using the same photolithography and etching steps, eliminating the need for separate insulation formation steps and maintaining high production efficiency while suppressing leak current.
Solution Approach 2:
The patent makes the electrode structure itself serve dual functions: as the conductive electrode and as the insulation structure. By forming insulation layers on the side faces and using the electrode pattern geometry, the same structural elements perform both electrical conduction and electrical insulation functions, reducing the need for additional dedicated insulation components.
2Reliability
If a black matrix is formed to cover side faces of electrodes, then leak current is suppressed, but device complexity increases
Solution Approach 1:
The patent merges the insulation structure with the electrode structure by forming insulation layers on the side faces of the electrodes during the same fabrication process. This integration reduces structural complexity compared to adding a separate black matrix layer, while still achieving effective leak current suppression.
3Ease of manufacture
If light emitting layer thickness is reduced in side face regions, then manufacturing is simplified, but leak current increases and light emission uniformity deteriorates
Solution Approach 1:
The patent applies different thickness characteristics to different regions of the light emitting layer. The side face regions have reduced thickness to simplify manufacturing, while insulation layers are selectively formed on these side faces to prevent leak current. This local differentiation allows manufacturing simplification without compromising reliability.
4Reliability
If electrode gap regions are covered with insulation material, then leak current is suppressed, but open face rate decreases
Solution Approach 1:
The patent selectively forms insulation layers only on the side faces of the electrodes where leak current occurs, rather than covering the entire electrode gap region. This localized approach suppresses leak current while minimizing the impact on the open face rate, as the insulation is confined to specific high-risk areas rather than blanket coverage.
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 solution effectively suppresses leak current, maintains high displaying quality and reliability, and extends the lifespan of light emitting layers by preventing unnecessary current flow through side face regions, while simplifying the production process.
Implementation Method 1
bringing an insulation characteristics imparting processing gas into contact with the electrical conductor layer by the utilization of the resist pattern as a mask, the insulation characteristics imparting processing gas causing a composition of corresponding regions of the electrical conductor layer to alter
Data Source
AI summary
Electrodes are formed in a predetermined pattern on a base plate. Side face regions of each electrode or certain regions of each electrode, which certain regions contain the side face regions and neighboring regions, have a composition different from the composition of the other region and have insulation characteristics. The base plate with electrodes is produced with a process wherein a conductor layer is formed on the base plate, a resist pattern is formed on the conductor layer, the conductor layer is etched with the resist pattern acting as a mask, the electrodes being thereby formed in the predetermined pattern, and an insulation characteristics imparting processing gas is brought into contact with the electrodes.