Light-Emitting Element Electrode Patterning With Insulating Recesses
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Solution Overview
Problem
Existing display devices require a large number of manufacturing steps, particularly in the process of fixing light-emitting elements with electrode layers and patterning these layers, which increases complexity and costs.
Innovation Solution
The display device incorporates a method where light-emitting elements are fixed with an electrode layer that forms contact electrodes, and an insulating layer is used to pattern the electrode layer, reducing the number of manufacturing steps and mask processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light-emitting elements are fixed with a separate electrode layer and patterned with mask processes, then the light-emitting elements can be securely fixed and electrically connected, but the number of manufacturing steps increases and production complexity increases
Solution Approach 1:
The patent combines the electrode layer and insulating layer into a single integrated structure. The insulating layer is formed with a recess that directly exposes the electrode, eliminating the need for separate masking steps. This merging of functions reduces manufacturing complexity while maintaining reliable electrical connection and fixation of light-emitting elements.
Solution Approach 2:
The insulating layer serves multiple functions: it provides electrical insulation, defines the electrode pattern through its recess structure, and supports the light-emitting elements. This multi-functionality eliminates the need for dedicated mask layers, reducing the number of manufacturing steps while maintaining process reliability.
2Manufacturing precision
If multiple mask processes are used to pattern the electrode layer, then precise patterning can be achieved, but the number of manufacturing steps increases and production time increases
Solution Approach 1:
The insulating layer is formed in advance with a pre-defined recess structure that directly determines the electrode pattern. This preliminary structuring eliminates the need for subsequent masking steps, achieving precise patterning while significantly reducing the number of manufacturing steps and improving production efficiency.
3Ease of manufacture
If separate electrode layer and insulating layer are used, then functional separation is achieved, but the number of manufacturing steps increases
Solution Approach 1:
The patent merges the formation of the electrode layer and insulating layer into a single manufacturing step. The insulating layer is deposited with a recess that directly exposes the electrode, achieving functional separation (electrode for conduction, insulating layer for isolation) without requiring separate processing steps, thus reducing manufacturing cycle time.
Data Source
AI summary
A display device and a method of fabricating a display device are provided, the display device comprising a first substrate, first and second electrodes on the first substrate and spaced apart from each other, a first insulating layer covering portions of the first and second electrodes, light-emitting elements on the first insulating layer, a first contact electrode on the first electrode and in contact with first end portions of the light-emitting elements, a second insulating layer on the light-emitting elements and covering a first end portion of the first contact electrode, and a second contact electrode between the second insulating layer and the second electrode, and in contact with second end portions of the light-emitting elements.