High-Precision LED Display Manufacturing with Patterned Pixel Landings
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Summary
Problems
Existing methods for forming addressable displays using microscopic printed LEDs face challenges such as precise registration of metal and LED ink patterns, lower quality of printed metal layers, difficulty in patterning ink for large displays, and inability to print small pixels.
Innovation solutions
A metal landing pixel pattern is formed on a flexible substrate using techniques like laminating a thin metal film and patterning, followed by blanket-printing LEDs over the pattern, with a dielectric and transparent conductor layer to create addressable pixels, allowing for precise control and high-quality metal usage.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If metal ink is printed to form pixel patterns, then the process is simple and low-cost, but the registration precision between metal and LED ink patterns deteriorates
Why choose this principle:
The process is segmented into two independent stages: first printing the metal pixel pattern and curing it, then printing the LED ink pattern separately. This segmentation allows each layer to be optimized independently, with the metal pattern serving as a precise template that doesn't require alignment with subsequent layers.
Principle concept:
If metal ink is printed to form pixel patterns, then the process is simple and low-cost, but the registration precision between metal and LED ink patterns deteriorates
Why choose this principle:
The metal pixel pattern is printed and cured in advance before LED ink printing. This preliminary action creates a stable, high-precision template that defines the pixel locations, eliminating the need for complex real-time registration during the LED printing process.
Application Domain
Data Source
AI summary:
A metal landing pixel pattern is formed on a flexible substrate using techniques like laminating a thin metal film and patterning, followed by blanket-printing LEDs over the pattern, with a dielectric and transparent conductor layer to create addressable pixels, allowing for precise control and high-quality metal usage.
Abstract
Pixel locations in an addressable display are defined by metal landings on a top surface of a flexible substrate, such as by depositing a metal film and etching the film. The substrate surface may be hydrophobic so that the hydrophobic surface is exposed between the metal landings. The substrate has conductive vias that connect the metal landings to traces on a bottom surface of the substrate for connection to addressing circuitry. LED ink is then blanket-printed over the top surface and cured to electrically connect bottom electrodes of the LEDs to the metal landings. LEDs that fall between the landings are ineffective. A dielectric layer is blanket-printed which exposes the top electrodes, and a transparent conductor layer is blanket-printed over the LEDs to connect all LEDs associated with an individual pixel location in parallel. Accordingly, all printed steps can be performed without any alignment.