Insulating Layer Patterning for Stable Light-Emitting Element Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Display devices face challenges in preventing delamination of insulating layers covering light-emitting elements, particularly due to the long and narrow design of these layers which can lead to instability and performance issues.
Innovation Solution
The implementation of a display device design where a second insulating layer with extended portions and pattern portions is used, connecting to the first insulating layer and electrodes, ensuring a wider pattern portion than the extended portions to prevent delamination and stabilize the light-emitting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the insulating layer is designed with long length and narrow line width to cover light-emitting elements, then the alignment location fixing capability is improved, but the layer becomes prone to delamination
Solution Approach 1:
The insulating layer is segmented into multiple functional portions: narrow extended portions for alignment fixing and wide pattern portions for delamination prevention. This segmentation allows each portion to optimize its specific function while working together as an integrated structure.
Solution Approach 2:
Different portions of the insulating layer have different local qualities: the extended portions have narrow width for precise alignment, while the pattern portions have wide width for structural stability and delamination resistance. This local quality variation resolves the contradiction between precision and reliability.
2Manufacturing precision
If the insulating layer has narrow width to maintain precision alignment, then the alignment accuracy is improved, but the structural stability deteriorates
Solution Approach 1:
The insulating layer transitions from a one-dimensional narrow strip to a two-dimensional structure with both extended portions (narrow) and pattern portions (wide). This dimensional expansion provides structural stability without compromising the precision alignment function of the extended portions.
Solution Approach 2:
The wide pattern portions are preliminarily designed to prevent delamination before it occurs, providing structural stability in advance. This preliminary structural reinforcement allows the narrow extended portions to maintain alignment accuracy without compromising overall stability.
Data Source
AI summary
A display device comprises electrodes spaced apart from one another in a first direction and in a second direction intersecting the first direction, each of the electrodes having a shape extending in the second direction, a first insulating layer disposed on the electrodes, light-emitting elements disposed on the first insulating layer, each of the light-emitting elements including ends disposed on the electrodes spaced apart from one another in the first direction, and a second insulating layer at least partially disposed on the light-emitting elements. The second insulating layer comprises extended portions extending in the second direction, and at least one pattern portion connected to the extended portions. The at least one pattern portion includes a part having a width greater than a width of each of the extended portions in the first direction.