Micro-LED Display Electrode Layout for Mask-Lite Alignment

Solution Overview

Problem

The existing manufacturing processes for display devices with nano-scale to micro-scale light emitting elements require multiple masks, which complicates the production and limits the flexibility in design, particularly in achieving a flat upper surface.

Innovation Solution

A method and structure for a display device that reduces the number of masks needed by using a pixel circuit layer with protruding partition walls and electrodes, where light emitting elements are aligned between the electrodes, and organic patterns are formed directly on the electrodes, with contact electrodes positioned to facilitate electrical connection while maintaining a flat surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple masks are used in the manufacturing process to achieve precise positioning of light emitting elements, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvepositioning precision of light emitting elementsVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Protruding partition walls and electrodes are formed in advance during the pixel circuit layer fabrication process, creating pre-positioned structures that guide light emitting element placement. This preliminary structuring eliminates the need for separate masking steps for positioning, as the walls and electrodes themselves define the precise locations where light emitting elements should be placed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pixel circuit layer structures (partition walls and electrodes) serve dual purposes: they function as operational components of the display device and simultaneously serve as positioning guides for light emitting elements. The structures self-organize to create the necessary alignment features, eliminating the need for external masking tools.

Inventive Principle:

Principle #25Self-service

2Shape

If a complex multi-layer structure is used to achieve a flat upper surface, then surface flatness is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveflatness of upper surfaceVSAvoidalignment precision of multi-layer structures

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

Protruding partition walls and electrodes are formed in advance during the pixel circuit layer fabrication process, creating pre-positioned structures that guide light emitting element placement. This preliminary structuring eliminates the need for separate masking steps for positioning, as the walls and electrodes themselves define the precise locations where light emitting elements should be placed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pixel circuit layer structures (partition walls and electrodes) serve dual purposes: they function as operational components of the display device and simultaneously serve as positioning guides for light emitting elements. The structures self-organize to create the necessary alignment features, eliminating the need for external masking tools.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If additional organic patterns and contact electrodes are added to facilitate electrical connections, then ease of operation is improved, but device complexity increases

Engineering Contradiction:

Improveelectrical connection easeVSAvoidstructure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Contact electrodes are integrated directly into the pixel circuit layer, merging the electrical connection function with the existing circuit structures. This integration eliminates the need for separate connection components and reduces the number of discrete elements that would otherwise be required to establish electrical contacts with the light emitting elements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pixel circuit layer structures serve multiple functions simultaneously: they provide electrical connections, create positioning guides, define operational boundaries, and establish contact points for light emitting elements. This multi-functionality reduces the need for additional specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11749788B2Display device and method of manufacturing the same

Publication Date: 2023.09.05 SAMSUNG DISPLAY CO LTD

AI summary

A display device and a manufacturing method thereof are disclosed. The display device may include a pixel circuit layer including a plurality of transistors, a first partition wall and a second partition wall on the pixel circuit layer, and each protruding in a thickness direction, a first electrode and a second electrode formed on the same layer, and on the first partition wall and the second partition wall, respectively; a light emitting element between the first electrode and the second electrode; and a first organic pattern directly on the light emitting element.