Flat Panel Display Capping Layer Prevents Electrical Shorts
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Solution Overview
Problem
Flexible flat panel displays using plastic substrates face challenges in forming conventional polysilicon-series TFTs due to the need for low-temperature processes, and organic semiconductors are prone to damage during wet processes, leading to electrical short-circuits in pixel circuits.
Innovation Solution
A flat panel display design featuring an insulating film with apertures exposing pixel electrodes, conductors formed on the film, and a capping layer to cover the conductors, preventing electrical shorts by insulating and passivating the conductor surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If organic semiconductor is used to enable low-temperature process on plastic substrate, then TFT can be formed on flexible substrate, but the organic semiconductor is easily damaged during subsequent wet process causing electrical short-circuit
Solution Approach 1:
The patent introduces an insulating film as an intermediary layer between the organic semiconductor and subsequent conductive layers. This insulating film protects the sensitive organic semiconductor from damage during wet processes while preventing electrical short-circuits between conductors and electrodes.
Solution Approach 2:
The insulating film is formed in advance before subsequent conductor formation steps, creating a protective barrier that prevents potential electrical short-circuits before they can occur. This preliminary protective action ensures the organic semiconductor remains intact throughout the manufacturing process.
2Device complexity
If conductor is formed directly on insulating film with rough surface, then manufacturing process is simplified, but electrical short-circuit occurs between conductor and electrode
Solution Approach 1:
The insulating film serves as a mediator layer that covers the rough surfaces of electrodes and conductors, providing electrical insulation without requiring complex surface preparation or additional buffer layers, thus maintaining manufacturing simplicity while ensuring electrical reliability.
Data Source
AI summary
A flat panel display capable of preventing a pixel circuit from electrically short-circuiting, and a method of manufacturing the flat panel display are disclosed. In one embodiment, the flat panel display includes an insulating film having an aperture, a pixel electrode having a portion exposed by the aperture of the insulating film, a conductor formed on the insulating film, and a capping layer covering the conductor. According to embodiments of the present invention, the conductor is formed from a conductive paste and the rough surface of the conductive paste is passivated by a capping layer formed on the conductor, and thus, a short circuit between the conductor and an opposing pixel electrode can be prevented.