Display Device Insulation for Hydrophilic–Hydrophobic Pixel Alignment
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Solution Overview
Problem
Existing display devices face challenges in aligning light-emitting elements between neighboring pixels and efficiently disposing them in specific regions, particularly when pixel sizes are reduced.
Innovation Solution
A display device with a first insulating layer having hydrophilic and hydrophobic areas, where light-emitting elements are selectively positioned in the hydrophilic areas, minimizing their presence in non-emission regions and ensuring precise alignment without additional structural barriers between pixels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional structural barriers are added between pixels to prevent misalignment, then alignment precision improves, but device complexity increases
Solution Approach 1:
The substrate surface is modified to have self-aligning properties through hydrophilic/hydrophobic region separation. Light-emitting elements automatically align to specific regions during the transfer process without requiring external alignment structures or complex positioning mechanisms, achieving self-service alignment that reduces device complexity while maintaining precision
Solution Approach 2:
The patent replaces mechanical alignment structures (such as physical barriers or positioning features) with a chemical/surface property-based alignment system. By creating hydrophilic and hydrophobic regions on the substrate, the alignment function is achieved through surface energy differences rather than mechanical constraints, simplifying the overall device structure
2Area of moving object
If pixel size is reduced to increase display resolution, then display density improves, but alignment difficulty increases
Solution Approach 1:
The self-aligning substrate surface provides automatic positioning functionality that is particularly effective for small pixel sizes. During the transfer process, light-emitting elements naturally migrate to and align with the hydrophilic regions, ensuring precise placement even when pixel dimensions are reduced, thereby maintaining alignment precision without increasing manufacturing difficulty
Solution Approach 2:
The patent changes the surface energy parameters of the substrate by creating regions with different hydrophilic/hydrophobic characteristics. This parameter change enables the substrate to actively participate in the alignment process, providing a scalable solution that maintains alignment precision across different pixel size scales
3Productivity
If light-emitting elements are densely packed to reduce pixel size, then display resolution improves, but misalignment defects increase
Solution Approach 1:
The self-aligning substrate surface ensures that even when light-emitting elements are densely packed, each element automatically finds its correct position during transfer. This self-service alignment mechanism prevents misalignment defects and ensures high reliability in high-resolution displays with densely packed pixels
Solution Approach 2:
The substrate surface is segmented into distinct hydrophilic and hydrophobic regions, creating separate alignment zones for each pixel location. This segmentation ensures that light-emitting elements are directed to specific positions, preventing misalignment even in densely packed high-resolution configurations
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
This approach enhances the alignment of light-emitting elements within pixels, reducing defects and ensuring uniform light emission even with smaller pixel sizes, while minimizing the number of misplaced elements during manufacturing.
Implementation Method 1
A display device with a first insulating layer having hydrophilic and hydrophobic areas, where light-emitting elements are selectively positioned in the hydrophilic areas
Data Source
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AI summary
Provided are a display device and a manufacturing method thereof. The display device comprises: a substrate; a first electrode and a second electrode disposed on the substrate to be spaced apart from each other; a first insulating layer disposed on the substrate so as to cover at least a portion of the first electrode and the second electrode; and at least one first light emitting element disposed between the first electrode and the first electrode, on the first insulating layer. The first insulating layer comprises: a first sub-insulating layer comprising a first portion including a hydrophilic material and a second portion which is a region excluding the first portion and includes a hydrophobic material; and a second sub-insulating layer disposed below the first sub-insulating layer, wherein at least a portion of the at least one first light emitting element is disposed on the first portion.