Pixel Bank Pattern Layout for Precise Light Emitter Alignment
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Solution Overview
Problem
Current display device manufacturing processes are complex and inefficient due to the need for separate dam structures and multiple masks, which complicate the alignment and arrangement of light emitting elements, leading to increased costs and reduced light emission efficiency.
Innovation Solution
A pixel structure with bank patterns and a hydrophilic insulating layer that simplifies the manufacturing process by controlling the supply and arrangement position of light emitting elements, eliminating the need for separate dam structures and reducing the number of masks required, while enhancing light efficiency through improved alignment and emission area design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate dam structures and multiple masks are used to control light emitting element arrangement, then alignment precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the dam structure and bank pattern into a single integrated structure. The bank pattern serves dual functions: it acts as a dam to confine the liquid crystal material and as a structural element to define the light emitting element arrangement area, eliminating the need for separate dam structures and reducing mask complexity
Solution Approach 2:
The bank pattern is designed to perform multiple functions simultaneously: it confines the liquid crystal material, defines the light emitting element arrangement area, and provides structural support for the light emitting elements. This multi-functionality reduces the overall device complexity while maintaining manufacturing precision
2Reliability
If separate dam structures are used to confine liquid crystal material, then material confinement is improved, but manufacturing process complexity increases
Solution Approach 1:
The dam structure and bank pattern are merged into a single integrated component. The bank pattern's raised structure serves as the dam to confine the liquid crystal material, eliminating the need for separate dam structures and simplifying the manufacturing process while maintaining effective material confinement
3Manufacturing precision
If multiple masks are used for light emitting element arrangement, then placement precision is improved, but manufacturing time and cost increase
Solution Approach 1:
The bank pattern is formed in advance with the precise geometry needed to define the light emitting element arrangement area. This preliminary structuring allows subsequent light emitting element placement to be performed more efficiently with fewer masks, as the bank pattern already provides the necessary alignment references and confinement boundaries
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed solution simplifies the manufacturing process, reduces costs, and enhances light emission efficiency by allowing for precise control of light emitting element placement and alignment within the pixel structure, thereby improving the overall performance of the display device.
Implementation Method 1
a first insulating layer at a portion of the pixel area including the first area to cover the first electrode and the second electrode, and removed from another portion of the pixel area including opposite edge portions to expose the bank patterns
Implementation Method 2
The first insulating layer may include a hydrophilic surface, and the bank patterns may include a hydrophobic surface
Data Source
AI summary
A display device includes a base layer including a pixel area, and a pixel in the pixel area. The pixel includes a first area, and a second area enclosing the first area in a plan view, bank patterns at the pixel area, extending in a first direction, spaced from each other by a first distance in the first area, and spaced from each other by a third distance that is greater than the first distance in the second area, a first electrode and a second electrode at an area of the bank patterns, and spaced from each other by a second distance that is less than the first distance in the first area, a first insulating layer at a portion of the pixel area including the first area to cover the first electrode and the second electrode and removed from another portion of the pixel area including opposite edge portions.