Light-Emitting Element Fixation Using Adhesive and Insulating Layers

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Solution Overview

Problem

Existing display device fabrication methods face challenges in achieving high yield and reliability due to the need for high-temperature processes and potential damage to components, especially in fixing light-emitting elements to pixel electrodes.

Innovation Solution

A method involving the use of an adhesive layer, such as silver paste, to temporarily fix light-emitting elements to pixel electrodes, followed by an insulating layer that completely fixes them, allowing for low-temperature processing and reducing component damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high-temperature processes are used to fix light-emitting elements, then fixation reliability is improved, but component damage and surface defects increase

Engineering Contradiction:

Improvefixation reliabilityVSAvoidcomponent damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the temperature parameter from high-temperature processing to low-temperature processing (using adhesive layers cured at lower temperatures), thereby achieving reliable fixation without causing component damage or surface defects associated with high temperatures

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces an adhesive layer as an intermediary substance between the light-emitting element and the substrate, which enables reliable fixation through chemical bonding at low temperatures, avoiding the need for high-temperature direct bonding that causes damage

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If high-temperature processes are used, then fixation strength is improved, but production costs increase due to process complexity

Engineering Contradiction:

Improvefixation strengthVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the curing temperature parameter to low temperature, simplifying the manufacturing process and reducing equipment requirements while maintaining adequate fixation strength through the adhesive layer

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a consumable adhesive layer that provides sufficient fixation strength for the application, replacing expensive and complex high-temperature bonding processes with a simpler, more cost-effective solution

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Temperature

If adhesive layer is used for fixation, then low-temperature processing is enabled, but initial fixation stability is reduced

Engineering Contradiction:

Improveprocessing temperatureVSAvoidfixation stability

Core Design Contradiction:

TemperatureVSStability of the object's composition

Solution Approach 1:

The patent applies the adhesive layer in advance before mounting the light-emitting element, allowing the adhesive to be properly positioned and prepared, which compensates for the initially lower stability compared to high-temperature bonding

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The adhesive layer acts as an intermediary that provides adequate fixation stability for the specific application requirements, enabling low-temperature processing while maintaining sufficient mechanical and chemical bonding

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach improves the yield and reduces production costs by avoiding high-temperature processes and minimizing surface defects, while ensuring reliable fixation of light-emitting elements.

Implementation Method 1

an adhesive layer on the pixel electrode, placing a light-emitting element on the adhesive layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

forming an insulting layer to cover the transistor, the pixel electrode, and the light-emitting element

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS20250022862A1Display device and method of fabricating the same

Publication Date: 2025.01.16 SAMSUNG DISPLAY CO LTD

AI summary

A method of fabricating a display device includes forming a transistor above a substrate, and a pixel electrode at a same layer as one of electrodes of the transistor, forming an adhesive layer on the pixel electrode, placing a light-emitting element on the adhesive layer, forming an insulting layer to cover the transistor, the pixel electrode, and the light-emitting element, and forming a first bridge pattern electrically connecting the transistor to a first end of the light-emitting element, and a second bridge pattern electrically connected to a second end of the light-emitting element, wherein the light-emitting element is primarily fixed by the adhesive layer, and wherein the light-emitting element is secondarily fixed by the insulating layer.