Light-Emitting Element Insulating Structure for Surface Defect Control
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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 method of manufacturing light-emitting elements involves forming areas with different diameters and using insulating films to cover these areas, including a first insulating film directly on the first area and a second insulating film on the second area, which is exposed by the first insulating film, to protect the semiconductor layers and active layer, thereby reducing surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single insulating film structure is used, then the manufacturing process is simple, but surface defects occur and electrical stability deteriorates
Solution Approach 1:
The insulating film is divided into multiple distinct layers (first insulating film, second insulating film, and third insulating film) with different functions. The first insulating film provides baseline insulation, the second insulating film protects the active layer during etching, and the third insulating film provides final protection and planarization. This segmentation resolves the contradiction by improving electrical stability through functional specialization while managing complexity through systematic layer design.
Solution Approach 2:
The second insulating film is formed before the secondary etching process to protect the active layer in advance. This preliminary protective action prevents surface defects from occurring during the etching process, thereby improving reliability before the harmful effect can manifest. The protective layer is strategically placed ahead of time to counteract potential damage.
2Ease of manufacture
If the active layer is exposed during manufacturing, then electrical connections can be made, but surface defects and damage to the active layer occur
Solution Approach 1:
The second insulating film is formed as a protective layer before the secondary etching process that would otherwise expose the active layer. This preliminary protection allows the manufacturing process to proceed while the active layer remains covered, preventing surface defects. Electrical connections are subsequently established through contact holes formed in the insulating films after protection is no longer needed.
Solution Approach 2:
The second insulating film acts as an intermediary protective barrier between the active layer and the etching process. It mediates the conflict by allowing the etching to proceed (maintaining ease of manufacture) while simultaneously protecting the active layer from damage (maintaining reliability). The intermediary layer is removed or opened only where electrical connections are required.
3Productivity
If conventional manufacturing processes are used, then production is efficient, but surface defects reduce the lifetime of light-emitting elements
Solution Approach 1:
The protective second insulating film is formed in advance before the secondary etching process, preventing surface defects from occurring during manufacturing. This preliminary protection ensures that the light-emitting elements are defect-free from the start, thereby extending their operational lifetime without significantly impacting manufacturing efficiency, as the protective layer formation is integrated into the existing process flow.
Solution Approach 2:
The second insulating film serves as a cushioning protective layer that absorbs potential damage during the secondary etching process. By providing this beforehand cushioning, surface defects are prevented, and the light-emitting elements maintain their integrity throughout the manufacturing process, leading to improved lifetime while maintaining productivity.
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.