Light-Emitting Element Layout Using Asymmetry and Fusible Alloy Alignment
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Solution Overview
Problem
Existing display devices face challenges in enhancing light emission efficiency, particularly in portable information media, where the alignment and arrangement of light emitting elements are critical for optimal performance.
Innovation Solution
A display device design featuring light emitting elements with asymmetrical surfaces and a metal layer comprising fusible or eutectic alloys, aligned using magnetic materials, and an insulating film to prevent short circuits, along with a bank and light conversion layers to enhance light emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If light emitting elements are arranged closely to increase density, then productivity and display resolution are improved, but misalignment and manufacturing precision deteriorate
Solution Approach 1:
The patent applies asymmetry by making the first surface area of light emitting elements different from the second surface area, creating a truncated pyramid or truncated cone shape. This asymmetric geometry enables the elements to self-align and self-arrange in predetermined orientations, solving the misalignment problem that occurs when elements are densely packed. The smaller first surface contacts the first electrode while the larger second surface contacts the second electrode, ensuring correct orientation even at high densities.
2Manufacturing precision
If asymmetrical shapes are used for self-alignment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by modifying only specific geometric properties of the light emitting elements (the surface areas of the first and second surfaces) while maintaining the overall simplicity of the device structure. The asymmetric shape is implemented locally at the element level rather than requiring complex system-wide changes. This localized geometric modification enables self-alignment without significantly increasing overall device complexity.
3Ease of manufacture
If fusible alloys with low melting points are used for alignment, then ease of manufacture is improved, but temperature control becomes more critical
Solution Approach 1:
The patent applies phase transitions by utilizing the melting and solidification behavior of fusible alloys (such as Field's metal, Galinstan, or Cerrolow) to achieve alignment. The low melting point (200-300°C) of these alloys allows them to be easily melted and re-solidified during the alignment process, enabling simple yet effective positioning of light emitting elements. The phase change from liquid to solid provides a natural locking mechanism that secures elements in their aligned positions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design improves light emission efficiency and alignment, reducing misarrangement of light emitting elements, thereby enhancing the performance of display devices, particularly in portable information media.
Implementation Method 1
a metal layer in contact with the first electrode and including a fusible alloy and/or a eutectic alloy
Implementation Method 2
aligned using magnetic materials
Data Source
AI summary
A display device includes a substrate, a first electrode on the substrate, a plurality of light emitting elements on the first electrode, and a second electrode on the plurality of light emitting elements. An area of a first surface of each of the plurality of light emitting elements in contact with the first electrode is different from an area of a second surface of each of the plurality of light emitting elements in contact with the second electrode. Each of the plurality of light emitting elements includes a metal layer in contact with the first electrode and including a fusible alloy or a eutectic alloy.