Micro-LED Display Optical Layer Layout for Accurate Element Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The transfer accuracy of light-emitting elements in display devices is affected by improper positioning, leading to defects such as non-transfer, over-transfer, and discontinuity or breakage of upper electrodes, which reduces transfer process efficiency and increases defects and power consumption.
Innovation Solution
The display device includes a substrate with a pixel driving circuit, an insulating layer, a bank layer, and optical layers surrounding the light-emitting element, with specific geometric configurations to maintain a consistent insulating film thickness and prevent upper electrode cracks, ensuring accurate transfer and continuous electrode formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the light-emitting element is transferred to the panel substrate, then the display device can be manufactured, but transfer accuracy problems occur leading to defects
Solution Approach 1:
The patent applies preliminary action by forming the insulating film on the lower electrode before the transfer process. This ensures that the insulating film is already in place with appropriate thickness to prevent cracks in the upper electrode after transfer, thereby preventing defects before they occur during the transfer process
Solution Approach 2:
The patent implements beforehand cushioning by ensuring a minimum thickness of the insulating film is maintained on the lower electrode. This cushioning layer prevents the upper electrode from cracking during transfer, thereby protecting against defects and improving transfer accuracy
2Reliability
If the upper electrode is formed in the light-emitting element, then electrical function is achieved, but cracks may occur reducing reliability
Solution Approach 1:
The patent applies beforehand cushioning by forming an insulating film with a minimum thickness on the lower electrode before depositing the upper electrode. This cushioning layer prevents cracks from propagating through the upper electrode, maintaining electrode integrity and reliability
Solution Approach 2:
The insulating film acts as an intermediary layer between the lower electrode and the upper electrode. This intermediary layer prevents direct stress transmission that would cause cracking, thereby maintaining upper electrode continuity and electrical function
3Productivity
If transfer process is performed, then light-emitting elements are positioned, but non-transfer defects occur reducing productivity
Solution Approach 1:
The patent applies preliminary action by preparing the insulating film structure before the transfer process. This preliminary preparation ensures that the light-emitting elements can be transferred successfully without non-transfer defects, improving both productivity and transfer completeness
Solution Approach 2:
The patent implements beforehand cushioning by ensuring adequate insulating film thickness is present before transfer. This cushioning prevents damage during transfer, reducing non-transfer defects and improving the overall transfer process success rate and productivity
Data Source
AI summary
Disclosed is a display device including a micro light-emitting element. The display device includes a substrate; a pixel driving circuit disposed on the substrate; an insulating layer disposed on the pixel driving circuit; a bank layer disposed on the insulating layer; a light-emitting element disposed on the bank layer and overlapping the bank layer; a first optical layer disposed so as to surround the light-emitting element; and a second optical layer disposed so as to surround the first optical layer, wherein a distance from an uppermost surface of the insulating layer to an uppermost end of the first optical layer is smaller than a distance from the uppermost surface of the insulating layer to an uppermost end of the second optical layer.