Micro-LED Display Electrode Layout Without Planarization Alignment
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Solution Overview
Problem
The existing techniques for fabricating display devices with micro light emitting elements are complex due to the need for precise alignment and emission processes, particularly with inorganic crystalline structures, which complicates the manufacturing process.
Innovation Solution
A display device design that includes a base layer with conductive patterns and insulating layers, where light emitting elements are positioned between electrodes without overlapping the conductive patterns, and an inorganic insulating layer is used to simplify the fabrication process by eliminating the need for additional planarization layers and alignment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a planarization layer is formed to align micro light emitting elements, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The patent applies preliminary action by forming the inorganic insulating layer with a recess region before placing the light emitting elements. This pre-prepared structural feature enables direct alignment of light emitting elements with conductive patterns without requiring additional planarization layers, thus improving alignment precision while avoiding increased fabrication complexity
Solution Approach 2:
The patent extracts and removes the planarization layer from the fabrication process. By using the inorganic insulating layer with a recess region instead, the patent eliminates the need for separate planarization steps while maintaining alignment precision, thereby reducing overall device complexity
2Manufacturing precision
If additional alignment and emission processes are required, then light emission control is improved, but productivity decreases
Solution Approach 1:
The patent merges the alignment function and emission control function into a single integrated structure. The inorganic insulating layer with its recess region simultaneously provides alignment guidance and enables direct electrical connection to conductive patterns, eliminating separate alignment and emission processes while maintaining control precision and improving productivity
3Productivity
If light emitting elements overlap conductive patterns, then connection efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by creating a recess region in the inorganic insulating layer at specific locations where light emitting elements need to connect to conductive patterns. This localized structural modification allows direct connection without overlap, maintaining connection efficiency while reducing positioning precision requirements since the recess provides natural alignment guidance
Data Source
AI summary
A display device includes: a base layer having a first area and a second area extending at least partially around a periphery of the first area; conductive patterns in the second area; an insulating layer over the conductive patterns in the second area; a first electrode and a second electrode on the insulating layer; and a plurality of light emitting elements between the first electrode and the second electrode in the first area and being connected to the first electrode and the second electrode. The first electrode and the second electrode are spaced apart from each other in the first area and are respectively connected to portions of the conductive patterns through contact openings penetrating the insulating layer. The light emitting elements do not overlap the conductive patterns and the insulating layer.