Pixel-Defining Trench Crossing Layout for Void-Stable Displays

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Solution Overview

Problem

Existing display devices face challenges in maintaining reliability due to issues with voids and critical dimensions at the intersection of trenches in the pixel-defining layer, affecting the performance and integrity of the display.

Innovation Solution

Incorporating a dummy pattern between adjacent sub-pixels at the intersection of horizontal and vertical portions of the trench, using materials similar to the pixel-defining layer, to control voids and dimensions, ensuring consistent widths and distances, thereby stabilizing the structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a trench is formed at the intersection of horizontal and vertical portions in the pixel-defining layer, then the structure can define sub-pixel boundaries, but voids and critical dimension variations occur at the crossing portion reducing reliability

Engineering Contradiction:

Improvedisplay device reliabilityVSAvoidcritical dimension control at trench crossing

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

A dummy pattern is formed in advance at the crossing portion of the horizontal and vertical portions of the trench. This dummy pattern is created before the trench etching process, serving as a structural support that prevents void formation and maintains critical dimension consistency during subsequent manufacturing steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The dummy pattern acts as an intermediary element between the horizontal and vertical portions of the trench. It provides mechanical support and structural continuity at the crossing portion, preventing the formation of voids and ensuring uniform critical dimensions without interfering with the final trench structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If the pixel-defining layer is recessed to form the trench, then sub-pixel boundaries are defined, but the structural integrity at the crossing portion is compromised

Engineering Contradiction:

Improvetrench structure for sub-pixel definitionVSAvoidstructural integrity at trench crossing

Core Design Contradiction:

ShapeVSStability of the object's composition

Solution Approach 1:

The dummy pattern is formed in advance at the crossing portion before the trench recessing process. This preliminary structure provides continuous material support at the crossing portion, preventing structural instability and void formation that would otherwise occur during the trench formation process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The dummy pattern is specifically placed only at the crossing portion where structural integrity is most critical. This localized approach provides enhanced structural support precisely where needed, without affecting the overall trench shape or requiring changes to other parts of the pixel-defining layer.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250380603A1Display device, wearable electronic device, and method of manufacturing display device

Publication Date: 2025.12.11 SAMSUNG DISPLAY CO LTD

AI summary

One or more embodiments provides a display device including a substrate, sub-pixels respectively including a light-emitting area above the substrate, a planarization layer above the substrate, a pixel-defining layer above the planarization layer, a trench defined by a recessed portion of the pixel-defining layer in a non-light-emitting area surrounding the light-emitting area, and including a horizontal portion extending in a first direction, and a vertical portion extending in a second direction crossing the first direction, and a dummy pattern between adjacent ones of the sub-pixels in a crossing portion where the horizontal portion and the vertical portion cross.