Micro-LED Display Insulating Structure for Gap-Free Electrode Contact
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Solution Overview
Problem
Inorganic light emitting diodes in display devices face issues with interface defects and gaps in the insulating layer, leading to potential damage to light emitting elements and poor contact with electrodes during the manufacturing process.
Innovation Solution
An organic insulating layer is stacked on top of the inorganic insulating layer to fill inorganic crystal seams and gaps beneath the light emitting elements, preventing the expansion of these gaps and ensuring proper contact between the light emitting elements and electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an inorganic insulating layer is used to fix the light emitting element, then the light emitting element can be aligned and fixed, but crystal defects (seams) and gaps are formed around and below the light emitting element
Solution Approach 1:
The patent applies composite materials by combining an inorganic insulating layer (first insulating layer) with an organic insulating layer (second insulating layer). The organic insulating layer is formed to fill the crystal defects and gaps that remain in the inorganic insulating layer, creating a composite structure that leverages the advantages of both materials while compensating for their individual deficiencies.
Solution Approach 2:
The organic insulating layer is selectively formed only in regions where crystal defects and gaps are present, such as around the light emitting element and below the light emitting element. This local application approach targets specific problem areas without requiring complete replacement of the inorganic insulating layer, thus maintaining the overall structural integrity while improving local interface quality.
2Reliability
If a dielectrophoresis method is used to transfer inorganic light emitting diodes, then blue light efficiency and durability are improved, but interface defects and gaps are formed during the transfer process
Solution Approach 1:
The organic insulating layer is formed in advance during the manufacturing process, before final assembly and testing. This preliminary action ensures that interface defects and gaps are filled early in the process, preventing potential damage to the light emitting element and ensuring proper contact with electrodes in subsequent manufacturing steps.
Solution Approach 2:
The organic insulating layer acts as a cushioning layer that compensates for and prevents the harmful effects of interface defects and gaps. By providing this protective layer beforehand, the patent prevents potential damage to the light emitting element and ensures reliable electrical contact, cushioning against the adverse effects of the transfer process.
Data Source
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AI summary
A display device and method of manufacturing a display device. The display device includes a first electrode, a second electrode facing the first electrode, a first insulating layer on the first electrode and the second electrode and between the first electrode and the second electrode, a light emitting element on the first insulating layer, a second insulating layer covering the light emitting element and exposing end portions of the light emitting element, a third insulating layer on the second insulating layer, a first contact electrode electrically connected to the first electrode, on the third insulating layer and in contact with a first end portion of the light emitting element exposed by the second insulating layer, and a second contact electrode electrically connected to the second electrode, on the third insulating layer and in contact with a second end portion of the light emitting element exposed by the second insulating layer.