Inorganic LED Display Electrode Layout With Fewer Mask Steps
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Solution Overview
Problem
The manufacturing process for inorganic light emitting diodes is complex and requires multiple masks, limiting efficiency and durability compared to organic light emitting diodes.
Innovation Solution
A display device and method involving nano-scale to micro-scale light emitting elements with reduced mask usage, featuring a pixel circuit layer, partition walls, electrodes, and a semiconductor pattern that connects the light emitting element upon voltage application, with an insulating layer and contact electrodes for enhanced electrical stability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional inorganic light emitting diode manufacturing process is used, then the light emitting element can be formed, but the process requires multiple masks which increases manufacturing complexity and reduces productivity
Solution Approach 1:
The patent combines multiple mask functions into a single mask structure. The mask includes a first mask region for forming the light emitting element and a second mask region for forming the electrode, allowing both structures to be created in one photolithography step instead of requiring separate masking processes.
Solution Approach 2:
The single mask structure serves multiple functions: it defines the light emitting element pattern, defines the electrode pattern, and provides alignment references for both structures. This multi-functional mask reduces the total number of masking operations needed in the manufacturing process.
2Manufacturing precision
If multiple masks are used in the manufacturing process, then precise patterning can be achieved, but the manufacturing time and process complexity increase
Solution Approach 1:
The patent merges the patterning functions of multiple masks into a single integrated mask structure that can simultaneously define both the light emitting element and electrode patterns with precise alignment, maintaining patterning accuracy while reducing the number of sequential steps required.
3Ease of manufacture
If organic light emitting diodes are used, then the manufacturing process is simpler, but the durability and blue light efficiency are reduced compared to inorganic light emitting diodes
Solution Approach 1:
The patent changes the material parameter from organic to inorganic semiconductor material, which fundamentally alters the durability and efficiency characteristics while the simplified mask process addresses the manufacturing complexity concern.
Data Source
AI summary
A display device includes: a pixel circuit layer including a plurality of transistors; first partition wall and a second partition wall on the pixel circuit layer, each of the first and second partition walls having a shape protruding in a thickness direction; a first electrode and a second electrode on the same layer and respectively on the first partition wall and the second partition wall; a light emitting element between the first electrode and the second electrode; and a semiconductor pattern directly on the first electrode.