Pixel Electrode and Coating Layout for Low-Heat Color Conversion Displays
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Solution Overview
Problem
Existing display devices face challenges in manufacturing complexity and high costs due to the use of multiple masks in the manufacturing process, and there is a need to improve the reliability of the color conversion layer by minimizing heat transmission from the light emitting element.
Innovation Solution
The display device incorporates a coating layer made of acryl, polyimide, or siloxane between the light emitting element and the color conversion layer, with pixel electrodes on the same layer and spaced apart by an insulating pattern, and reduces the number of masks in the manufacturing process by forming the electrodes in the same process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the manufacturing process to form pixel electrodes and insulating patterns separately, then the manufacturing precision and reliability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the formation of pixel electrodes and insulating patterns into a single mask process. The mask pattern includes both electrode regions and insulating pattern regions, allowing both structures to be formed simultaneously in one step, thereby reducing manufacturing process complexity while maintaining positioning precision
Solution Approach 2:
The single mask serves multiple functions: it defines the pixel electrode positions, defines the insulating pattern positions, and establishes the spatial relationship between electrodes and insulating patterns. This multi-functional mask reduces the total number of manufacturing steps required
2Reliability
If a coating layer is added between the light emitting element and the color conversion layer to minimize heat transmission, then the reliability of the color conversion layer is improved, but the device complexity increases
Solution Approach 1:
The patent introduces a coating layer as an intermediary structure between the light emitting element and the color conversion layer. This coating layer acts as a thermal barrier that minimizes heat transmission to the color conversion layer, protecting it from thermal damage while maintaining the functional relationship between the light emitting element and color conversion layer
Solution Approach 2:
The coating layer is formed using organic materials such as acryl, polyimide, or siloxane, which have appropriate thermal properties to block heat transmission. These materials are deposited as thin films to create an effective thermal barrier without significantly increasing device complexity
3Reliability
If the coating layer does not contact the insulating pattern, then the reliability is improved by preventing electrical issues, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies different properties to different regions: the coating layer is positioned to cover the pixel electrodes while intentionally excluding the insulating pattern regions. This local differentiation ensures electrical insulation reliability by preventing contact between the conductive coating layer and insulating patterns, while the mask design automatically maintains the required positioning precision
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
This approach simplifies the manufacturing process, reduces costs, and enhances the reliability of the color conversion layer by minimizing heat transfer, thereby improving light output efficiency.
Implementation Method 1
a coating layer disposed on the first and second pixel electrodes and including a flat surface... The coating layer may not contact the insulating pattern... to minimize heat transmission from the light emitting element
Data Source
AI summary
A display device includes a pixel disposed in a display area of a substrate and including an emission area and a non-emission area. The pixel includes a light emitting element disposed in the emission area and including a first end and a second end facing each other in an extending direction, a first pixel electrode electrically connected to the first end of the light emitting element, a second pixel electrode electrically connected to the second end of the light emitting element, an insulating pattern disposed on the light emitting element to expose the first and second ends and including a first surface contacting the light emitting element, and a second surface facing the first surface in a thickness direction of the substrate, and a coating layer disposed on the first and second pixel electrodes and including a flat surface. The coating layer does not contact the insulating pattern.