Insulating Layer Electrode Alignment in Display Devices
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Solution Overview
Problem
Display devices face challenges in maintaining precise alignment of light emitting elements and preventing short circuits due to process dispersion and residual layers during electrode formation, which affects the accuracy of electrode spacing and contact with light emitting elements.
Innovation Solution
A display device design featuring a first and second electrode spaced apart by an insulating layer, where the insulating layer contacts the electrodes and secures a consistent gap, preventing misalignment and short circuits by forming the electrodes after the insulating layer is established, using a combination of wet and dry etching processes to ensure precise spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrodes are formed directly on the substrate without an insulating layer, then the manufacturing process is simpler, but process dispersion occurs leading to misalignment of light emitting elements
Solution Approach 1:
The insulating layer is formed in advance before the electrodes are deposited. This preliminary action establishes a reference plane that guides subsequent electrode formation, ensuring consistent spacing and preventing misalignment of light emitting elements while maintaining process simplicity.
2Area of stationary object
If electrodes are formed close together to reduce device size, then the device becomes more compact, but short circuits occur due to residual layers from poor etching
Solution Approach 1:
The insulating layer acts as an intermediary barrier between adjacent electrodes. By providing this intermediate layer, the patent enables electrodes to be positioned closer together for device miniaturization while preventing short circuits through the insulating barrier, even when residual layers are present from etching processes.
Solution Approach 2:
The insulating layer is formed before electrode deposition, establishing a protective barrier in advance. This preliminary insulation prevents short circuits between closely-spaced electrodes that may occur due to residual layers from subsequent etching or deposition processes.
3Reliability
If the insulating layer thickness is increased to prevent short circuits, then electrode insulation is improved, but the overall device thickness increases
Solution Approach 1:
The patent optimizes the insulating layer thickness parameter to achieve the minimum required insulation reliability while minimizing device thickness increase. By carefully controlling this parameter, the patent balances electrical insulation requirements with overall device compactness.
Data Source
AI summary
A display device includes a first electrode and a second electrode spaced apart from each other on a substrate; a first insulating layer disposed between the first electrode and the second electrode, and not overlapping the first electrode and the second electrode in a thickness direction of the first insulating layer; and a light emitting element disposed on the first insulating layer, wherein side surfaces of the first insulating layer contact the first electrode and the second electrode.