Light-Emitting Element Fixing Structure to Prevent Insulating Layer Peeling

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Solution Overview

Problem

Display devices face issues with the peeling off of insulating layers on light emitting elements, leading to separation and deterioration of display reliability, particularly due to the use of organic insulating materials which can be prone to damage during manufacturing steps.

Innovation Solution

A display device structure is implemented with a fixing pattern and a support pattern portion, where the fixing pattern is designed to contact the light emitting elements and a second insulating layer, and the support pattern portion is wider than the fixing pattern, ensuring stability and preventing peeling off by forming a connection between them, and using a combination of organic and inorganic insulating materials to enhance durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If organic insulating material is used to form insulating layers on light emitting elements, then ease of manufacture is improved, but reliability deteriorates due to peeling off during manufacturing steps

Engineering Contradiction:
Improveease of manufactureVSAvoidreliability
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The insulating layer is segmented into multiple distinct layers: a first insulating layer made of organic insulating material that contacts the light emitting element, and a second insulating layer made of inorganic insulating material that covers the first insulating layer. This segmentation allows each layer to perform its specific function - the organic layer provides ease of manufacture and good adhesion to the light emitting element, while the inorganic layer provides reliability and resistance to peeling during manufacturing steps.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent employs a composite structure combining organic and inorganic insulating materials in a layered configuration. The organic insulating material layer is formed first on the light emitting element, followed by the inorganic insulating material layer. This composite approach leverages the advantages of both material types - the organic material's ease of deposition and adhesion properties, and the inorganic material's structural stability and resistance to mechanical damage during subsequent manufacturing processes.

Inventive Principle:
Principle #40Composite materials

2Device complexity

If the insulating layer is made thinner to reduce device thickness, then device complexity is reduced, but strength deteriorates making it more prone to peeling

Engineering Contradiction:
Improvedevice complexityVSAvoidstrength
Core Design Contradiction:
Device complexityVSStrength

Solution Approach 1:

Rather than using a single thick insulating layer, the patent segments the insulation function into two thinner layers - an organic insulating layer and an inorganic insulating layer. Each layer can be optimized for its specific thickness and material properties, providing sufficient mechanical strength and peeling resistance without requiring excessive thickness, thus maintaining device compactness while improving reliability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The composite layered structure of organic and inorganic insulating materials provides enhanced mechanical strength and adhesion compared to a single-layer approach. The inorganic insulating material layer, in particular, provides a protective barrier that prevents peeling of the underlying organic layer during manufacturing steps, ensuring structural integrity without requiring the insulating structure to be excessively thick.

Inventive Principle:
Principle #40Composite materials

Data Source

PatentUS11978835B2Display device
Publication Date: 2024.05.07 SAMSUNG DISPLAY CO LTD
  • US11978835B2 patent drawing
  • US11978835B2 patent drawing
  • US11978835B2 patent drawing

AI summary

A display device includes a substrate; a first electrode and a second electrode disposed in an emission area and a sub-region and spaced apart from each other in a first direction; a first insulating layer disposed on the first electrode and the second electrode; light emitting elements disposed on the first insulating layer in the emission area, and including ends disposed on the first and second electrodes, respectively; and a second insulating layer disposed on the first insulating layer. The second insulating layer includes a fixing pattern; a support pattern portion; and a connection portion electrically connecting the fixing pattern and the support pattern portion, and the fixing pattern includes a first region that contacts an outer surface of the light emitting elements and a second region that does not contact the outer surface of the light emitting elements.