Method of making electroluminescent display panel with enlarged active display areas

Claim 1

Method of fabricating an electroluminescent display panel comprised of a thin planar insulating substrate having an X-Y array of display elements thereon each of which display elements include integral thin film transistor switching and control circuit elements disposed on the insulating substrate and interconnected by drive signal buses with an electrically insulative polymerized layer disposed over the thin film circuit elements and drive signal buses, and each display element including a plural level electroluminescent electrode disposed on the insulating substrate and extending over the insulative polymerized layer, with an electroluminescent phosphor layer disposed over the entire panel area in contact with the electroluminescent electrodes, which method comprises: (a) depositing the interconnected thin film circuit elements, signal buses and electroluminescent electrodes in sequence as an X-Y array on the planar insulating substrate; (b) laminating the relatively thick insulative photo-polymerizable layer over the entire panel side on which the thin film circuit elements are disposed; (c) directing photo-radiation through the substrate to photo-polymerize exposed areas of the photo-polymerizable layer which are not shielded by the opaque first level electrode and by the opaque thin film circuitry and buses, with the photo-polymerized area of the layer about the first level electrode at the bottom surface of the photo-polymerizable layer exceeding the area that is photo-polymerized at the upper surface of the layer so that a generally inverted conic unpolymerized layer portion extends above each first level electrode; (d) disposing an opaque photomask over the layer aligned with each first level electrode, with the opaque photomask area exceeding the first level electrode area and approximate the area of the unexposed upper surface above the first level electrode; (e) exposing the layer to photo-radiation directed from above the photomask to photo-polymerize the unexposed portion of the layer except for the area covered by the photomask; (f) removing unpolymerized portion of the layer; (g) vacuum depositing conductive metal electrodes over the insulative photo-polymerized layer to form the second level electrode portions and the connecting electrode portion which extend down to and contact the first level electrode portion; and (h) depositing an electroluminescent phosphor layer on the conductive metal electrodes and connecting electrode portions and onto the insulative photo-polymerized layer between the spaced electrode portions.