Pixel Electrode Protrusions for Void-Free Display Connections
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Solution Overview
Problem
The generation of voids in the connection electrode between the light emitting element and the circuit in display devices leads to a decrease in current density and luminance, which affects the performance of the display device.
Innovation Solution
The display device includes pixel electrodes with protrusions that are covered by connection electrodes, which are melt-bonded together, and is manufactured using a method that involves forming a first insulating layer, pixel electrodes with protrusions, and connection electrodes through chemical mechanical etching, followed by the formation of wavelength conversion layers and reflective layers to prevent void formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flat pixel electrodes are used, then the manufacturing process is simple, but voids form in the connection electrode leading to decreased current density and luminance
Solution Approach 1:
The pixel electrode is designed with a protrusion that curves upward toward the connection electrode, creating a convex surface. This curved geometry allows the connection electrode to wrap around and fully cover the protrusion, eliminating voids in the bonding interface and ensuring complete contact between the two electrodes.
Solution Approach 2:
The electrode structure transitions from a two-dimensional flat surface to a three-dimensional protruding form. The pixel electrode protrudes vertically from the substrate surface, creating a height dimension that enables the connection electrode to envelop it completely, achieving void-free bonding through spatial arrangement.
2Reliability
If the pixel electrode thickness is increased to cover the protrusion, then void formation is prevented, but the manufacturing precision requirements increase
Solution Approach 1:
The protrusion is formed on the pixel electrode before the connection electrode is applied. This preliminary structuring of the pixel electrode creates a predetermined geometry that guides the connection electrode formation process, ensuring that the connection electrode naturally covers the protrusion without requiring extreme thickness precision.
Solution Approach 2:
The design changes the geometric parameters of the electrode interface by creating a protrusion with specific height and radius. This parameter optimization allows the connection electrode to achieve complete coverage with moderate thickness, balancing void prevention with manufacturability.
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 solution prevents the generation of voids in the connection electrode, thereby maintaining current density and reducing the decrease in luminance, enhancing the display device's performance.
Implementation Method 1
The first connection electrode and the second connection electrode may be melt-bonded together
Implementation Method 2
forming a pixel electrode layer filling the contact holes and covering the first insulating layer, forming pixel electrodes each having a protrusion protruding over the first insulating layer by etching the pixel electrode layer and the first insulating layer
Data Source
AI summary
The disclosure provides a display device and a method of manufacturing the same. The display device includes a plurality of pixel circuit parts disposed on a substrate, a plurality of pixel electrodes, each disposed on the pixel circuit parts, a first insulating layer filling a space between the pixel electrodes, a plurality of light emitting elements, each disposed on the pixel electrodes, and connection electrodes disposed between the light emitting elements and the pixel electrodes. Each of the pixel electrodes includes a protrusion protruding toward a corresponding one of the connection electrodes.