3D Interdigitated LED Electrodes for Higher Connection Rate
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Solution Overview
Problem
Existing ultra-small LED electrode assemblies face low light extraction efficiency due to a significant number of ultra-small LED devices not being connected to the first and second electrodes.
Innovation Solution
The electrode assembly features a base substrate with interdigitated first and second electrodes having varying cross-sectional shapes, including semicircular, polygonal, and center-protruding designs, which enhance contact with ultra-small LED devices, ensuring a higher connection rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultra-small LED devices are arranged on interdigitated electrode lines using a solution application method, then the manufacturing process is simple and scalable, but a large number of LED devices fail to connect to both electrodes, reducing light extraction efficiency
Solution Approach 1:
The patent transitions from planar (2D) electrode lines to three-dimensional (3D) electrode structures with vertical protrusions. This dimensional change allows LED devices to be connected from multiple directions (top, bottom, and sides), significantly increasing connection probability while maintaining the simplicity of solution-based manufacturing.
Solution Approach 2:
The electrode structures are designed with non-uniform local characteristics - featuring protruding portions with larger cross-sectional areas at specific locations. These localized structural variations create preferential contact zones that enhance connection reliability without complicating the overall manufacturing process.
2Device complexity
If conventional planar electrode lines are used, then the device structure is simple, but the number of connected LED devices is insufficient, leading to low light extraction efficiency
Solution Approach 1:
The patent introduces vertical dimensionality to electrode structures through protruding portions extending upward from the substrate. This 3D configuration increases the effective contact area and volume available for LED device connection, thereby improving light extraction efficiency while adding minimal structural complexity.
Solution Approach 2:
The protruding portions of the electrodes are designed with curved or rounded cross-sections (circular, oval, or polygonal shapes) rather than sharp angular forms. This curvature facilitates better mechanical contact with spherical or cylindrical LED devices, enhancing connection reliability and light extraction performance.
Data Source
AI summary
Provided is a ultra-small light-emitting diode (LED) electrode assembly including a base substrate; an electrode line formed on the base substrate, and including a first electrode and a second electrode formed in a line shape to be interdigitated with each other while being spaced apart from each other; and at least one ultra-small LED device connected to the electrode line. A cross section of at least one of the first and second electrodes in a vertical direction has a height variation such that the first and second electrodes easily come in contact with the at least one ultra-small LED device.