Sub-Pixel Partition Wall Layout to Prevent LED Shorts
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Solution Overview
Problem
Existing display devices using subminiature light emitting diodes face challenges in manufacturing due to the potential for short-circuits between adjacent diodes, leading to defects and requiring complex manufacturing processes with multiple masks.
Innovation Solution
A display device design that includes a base layer with display and non-display areas, featuring pixels with sub-pixels comprising a partition wall, bank, and electrodes, where light emitting elements are positioned between electrodes, and a simplified manufacturing process with a reduced number of masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the manufacturing process to precisely position light emitting diodes, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The partition walls are formed in advance before the light emitting diodes are placed. This preliminary formation of the partition structure provides pre-defined positioning references, eliminating the need for multiple masks during the subsequent LED placement process. The partition walls serve as pre-prepared guides that automatically align the light emitting diodes during placement.
Solution Approach 2:
The partition walls act as intermediary structures between the substrate and the light emitting diodes. These partition walls provide a mediating interface that facilitates precise positioning of the light emitting diodes without requiring direct mask-based alignment. The partition walls translate the positioning requirement into a simpler physical alignment process.
2Productivity
If light emitting diodes are disposed in close contact to increase pixel density, then productivity is improved, but reliability deteriorates due to short-circuit risks
Solution Approach 1:
The partition walls divide the substrate surface into separate segmented regions, with each region housing individual light emitting diodes. This segmentation physically isolates adjacent light emitting diodes, preventing electrical short-circuits while allowing them to be disposed in close contact. Each partitioned region acts as an independent electrical zone, maintaining reliability despite high density arrangement.
Solution Approach 2:
The partition walls serve as intermediary insulating structures between adjacent light emitting diodes. These partition walls provide a physical and electrical barrier that prevents direct contact between the diodes, eliminating short-circuit risks while enabling close spacing. The partition walls mediate the interaction between neighboring diodes, allowing high density without compromising electrical isolation.
Data Source
AI summary
A display device may include: a base layer including a display area and a non-display area; and a plurality of pixels provided on the display area, and each including a plurality of sub-pixels. Each of the sub-pixels may include a pixel circuit layer, and a display element layer including an emission area formed to emit light, and a non-emission area provided around a perimeter of the emission area. The display element layer may include: a partition wall provided on the emission area of each of the sub-pixels; a bank provided on the non-emission area of each sub-pixel, and disposed on a surface equal to a surface on which the partition wall is disposed; a first electrode and a second electrode provided on the partition wall and spaced apart from each other; and at least one light emitting element provided between the first and second electrodes in the emission area of each sub-pixel, and configured to emit the light.