Integrated Pixel Layout for Fewer Masks and Better LED Alignment
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Solution Overview
Problem
Current display device manufacturing processes are complex due to the need for multiple masks, which can lead to misalignment of light emitting elements, resulting in reduced light output efficiency.
Innovation Solution
A display device design that integrates pixel circuit and display element parts on the same substrate, using a simplified manufacturing method with a reduced number of masks, where the interlayer insulating layer and insulating pattern share the same material, and the conductive layers are optimized to improve alignment and light emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the manufacturing process, then the manufacturing precision of light emitting element alignment is improved, but the device complexity and manufacturing process complexity increase
Solution Approach 1:
The patent merges the pixel circuit part and display element part into a single integrated structure on the same substrate. The insulating layer serves dual purposes: as a gate insulating layer for transistors and as a buffer layer for light emitting elements, eliminating the need for separate mask processes for each component type.
Solution Approach 2:
The insulating layer is designed to perform multiple functions simultaneously: it acts as a gate insulating layer in the pixel circuit region and as a buffer layer in the display element region. This multi-functionality reduces the number of manufacturing steps and masks required.
2Manufacturing precision
If multiple masks are used in the manufacturing process, then the manufacturing precision of light emitting element alignment is improved, but the productivity decreases
Solution Approach 1:
The patent combines the formation of pixel circuits and display elements into a single integrated manufacturing process. By using the same insulating layer for both transistor gates and light emitting element buffers, the number of masking steps is reduced, thereby improving manufacturing efficiency and productivity.
Solution Approach 2:
The insulating layer is formed in advance to serve as both the gate insulating layer for subsequent transistor fabrication and as the buffer layer for light emitting element placement. This preliminary action eliminates the need for separate mask processes, improving productivity.
3Ease of manufacture
If the insulating layer is used as both gate insulating layer and buffer layer, then the manufacturing process is simplified, but the manufacturing precision may be compromised
Solution Approach 1:
The insulating layer is designed with different local functions: in the pixel circuit region, it serves as a gate insulating layer, while in the display element region, it serves as a buffer layer. This local differentiation allows the single layer to meet the specific precision requirements of each region without compromising overall manufacturing precision.
Data Source
AI summary
A display device may include a substrate including a pixel area including a first area and a second area; and a pixel in the pixel area. The pixel may include: a pixel circuit part in the first area, the pixel circuit part including a bottom metal layer on the substrate, at least one transistor on the bottom metal layer, and an interlayer insulating layer provided on the transistor; and a display element part in the second area, the display element part including a plurality of light emitting elements to emit light, an insulating pattern on the plurality of light emitting elements, and a bank adjacent to the plurality of light emitting elements. The interlayer insulating layer and the insulating pattern may include the same material.