Transparent Polymer Electrode and Bank Pattern Etching for Displays
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Solution Overview
Problem
Current display device manufacturing processes are costly and inefficient due to the complexity of forming transparent conductive polymer components like contact electrodes and bank patterns, which require multiple masks and processes.
Innovation Solution
A method involving a transparent conductive polymer layer is used, where a single etching process forms both contact electrodes and a bank pattern simultaneously using a photoresist mask with varying transmissivity areas, reducing the need for multiple masks and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks and processes are used to form transparent conductive polymer components, then manufacturing precision is improved, but device complexity and processing cost increase
Solution Approach 1:
The patent combines multiple separate manufacturing processes into a single integrated process. Specifically, the bank pattern and contact electrodes are formed simultaneously in one etching step using a single photoresist mask, eliminating the need for multiple separate masks and etching processes that were traditionally required.
Solution Approach 2:
The single photoresist mask serves multiple functions: it defines both the bank pattern geometry and the contact electrode positions, acts as the etching mask for both features, and enables simultaneous formation of multiple components that traditionally required separate masking steps.
2Manufacturing precision
If multiple masks and processes are used to form transparent conductive polymer components, then manufacturing precision is improved, but processing time increases
Solution Approach 1:
The patent combines multiple separate manufacturing processes into a single integrated process. Specifically, the bank pattern and contact electrodes are formed simultaneously in one etching step using a single photoresist mask, eliminating the need for multiple separate masks and etching processes that were traditionally required.
Solution Approach 2:
The photoresist mask is designed with pre-defined patterns that simultaneously define both the bank pattern and contact electrode positions before the etching process begins, allowing both features to be created in a single operation rather than requiring sequential masking and etching steps.
3Device complexity
If a single etching process is used to form both contact electrodes and bank pattern, then device complexity is reduced, but manufacturing precision may worsen
Solution Approach 1:
The photoresist mask incorporates regions with different light transmissivity properties - some areas are more transparent to allow etching of contact electrodes, while other areas are less transparent to protect bank pattern regions. This local variation in mask quality enables precise differentiation of etching zones within a single mask structure.
Solution Approach 2:
The patent utilizes changes in the light transmissivity parameter of the photoresist mask to control the etching process. By designing mask regions with different transmissivity characteristics, the process achieves selective etching of contact electrode areas versus bank pattern areas, maintaining high precision despite using a single etching step.
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 lowers processing costs by streamlining the production of display devices while maintaining the necessary electrical conductivity and light transmissivity of the transparent conductive polymer components.
Implementation Method 1
etching the transparent conductive polymer layer using an etching mask, wherein the etching mask is the photoresist layer of which the at least part is removed
Data Source
AI summary
A display device may include a substrate, and a display element layer disposed on the substrate and including a light emitting element that emits light in a display direction. The display element layer may include a first contact electrode electrically connected to the light emitting element, a second contact electrode electrically connected to the light emitting element, and a bank pattern having a shape extending in the display direction. At least one of the first contact electrode, the second contact electrode, and the bank pattern may include a transparent conductive polymer.