Insulating Layer Patterning for LED Display Delamination Control
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 length and narrow width of these layers, which can lead to structural 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, and strategically placed to prevent delamination and maintain alignment of light-emitting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the insulating layer is made long and narrow to cover light-emitting elements, then the alignment function is improved, but delamination occurs reducing reliability
Solution Approach 1:
The insulating layer is divided into multiple segments: extended portions covering the light-emitting elements and pattern portions extending toward electrode regions. This segmentation allows each part to perform its specific function - the extended portions maintain alignment precision while the pattern portions provide delamination resistance through wider coverage areas.
Solution Approach 2:
The insulating layer design transitions from a simple linear extension to a two-dimensional structure with both extended portions (narrow, for alignment) and pattern portions (wider, for delamination prevention). This dimensional expansion solves the contradiction by adding functional breadth without compromising the linear alignment function.
2Reliability
If the insulating layer width is increased to prevent delamination, then reliability is improved, but the alignment precision is reduced
Solution Approach 1:
Different regions of the insulating layer have different width characteristics tailored to their specific functions. The extended portions maintain narrow width for precise alignment over the light-emitting elements, while the pattern portions have wider width for delamination resistance in the electrode regions. This local differentiation resolves the contradiction by applying appropriate width characteristics only where needed.
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.