Integrated Bank and Partition Wall for Lower-Cost LED Displays
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Solution Overview
Problem
The manufacturing costs of display devices, particularly those using inorganic light emitting diodes, are high due to the complexity and cost of forming partition walls and banks that define sub-pixel openings and trap coating solutions containing light emitting elements.
Innovation Solution
A method and structure for concurrently forming a partition wall and a bank using a halftone mask, where the bank serves as a dam to trap the coating solution, thereby reducing the need for multiple masks and lowering manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If partition walls and banks are formed separately using multiple masks, then the structural integrity and functionality are ensured, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the partition wall and bank into a single integrated structure formed by one mask pattern. The bank extends from the partition wall to form a continuous structure that performs both functions: defining sub-pixel openings and trapping coating solution. This merging eliminates the need for separate formation processes while maintaining structural integrity.
Solution Approach 2:
The integrated bank structure serves multiple functions simultaneously: it acts as a dam to trap coating solution containing light emitting elements, and the partition wall portion defines the sub-pixel openings. This multi-functional design reduces the number of components and manufacturing steps while ensuring both structural and functional requirements are met.
2Manufacturing precision
If multiple masks are used to form partition walls and banks, then precise positioning is achieved, but the manufacturing cost increases
Solution Approach 1:
The patent uses a single mask to simultaneously define both the partition wall and bank structures. The mask pattern includes regions that form the partition wall and regions that extend to form the bank, allowing precise positioning of both structures in one alignment step, thereby reducing manufacturing cost while maintaining positioning precision.
Solution Approach 2:
The bank structure is designed to extend from the partition wall in the mask pattern itself, preparing the integrated structure in advance. This preliminary design in the mask allows subsequent formation processes to create both structures simultaneously with precise positioning, eliminating the need for additional alignment and positioning steps.
3Reliability
If separate structures are formed for partition walls and banks, then functional performance is optimized, but the fabrication process becomes more complex
Solution Approach 1:
The patent merges the partition wall and bank into a single formed structure using one mask pattern. The integrated structure maintains the functional performance of separate structures while improving fabrication efficiency by reducing the number of formation steps, masks, and alignment operations required.
Solution Approach 2:
The integrated bank structure performs multiple functions that would traditionally require separate components: it defines sub-pixel openings through the partition wall portion and traps coating solution through the extended bank portion. This multi-functionality maintains optimized functional performance while simplifying the fabrication process and improving productivity.
Data Source
AI summary
A display device includes: a substrate, a partition wall on the substrate and defining an opening, a first bank on the substrate and integrally formed with the partition wall, a first electrode on the partition wall and the first bank, and a light emitting element located in the opening and electrically connected to the first electrode.