Light-Emitting Element Structure for Low-Defect Display Fabrication
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Solution Overview
Problem
Existing display devices face challenges in minimizing surface defects of light-emitting elements, which can affect the lifetime and efficiency of these elements.
Innovation Solution
A manufacturing method for light-emitting elements involves forming a first and second area with different diameters, using insulating films to cover the semiconductor layers, and incorporating inclined portions on the side surfaces to facilitate alignment and reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single insulating film is used to cover the light-emitting element, then the manufacturing process is simple, but surface defects occur during etching processes
Solution Approach 1:
The single insulating film is divided into two distinct insulating films: a first insulating film covering the first semiconductor layer and active layer, and a second insulating film covering the second semiconductor layer. This segmentation allows each film to be optimized for its specific protective function during different etching stages, preventing surface defects while maintaining manufacturing feasibility
Solution Approach 2:
The first insulating film is formed preliminarily before the second insulating film to protect the first semiconductor layer and active layer during the first etching process. This preliminary protective action ensures that critical layers are shielded before subsequent processing steps, reducing surface defects proactively
2Manufacturing precision
If the second area has a larger diameter than the first area, then alignment and coverage are improved, but the structural complexity increases
Solution Approach 1:
The light-emitting element structure intentionally employs asymmetry with two different area diameters. The first area has a smaller diameter while the second area has a larger diameter, creating an asymmetric configuration that improves alignment precision and coverage during manufacturing. This asymmetric design is simplified by forming the second insulating film to extend over the larger second area, naturally accommodating the dimensional difference without adding complex structural elements
Data Source
AI summary
A display device, a light-emitting element, and a method of manufacturing a light-emitting element are provided. A display device includes: a first electrode and a second electrode spaced apart from each other; and light-emitting elements between the first electrode and the second electrode, and each of the light-emitting elements includes a first area having a first diameter, a second area having a second diameter greater than the first diameter, a first insulating film surrounding the first area, and a second insulating film on the first insulating film, and the second insulating film surrounds the second area exposed by the first insulating film.