Bar-Type LED Support Structure for Precise Pixel Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in fabricating micro-bar-type LEDs lies in maintaining precise alignment and stability during subsequent processes, as their small size makes them prone to deviation, affecting the performance and durability of light emitting devices.
Innovation Solution
A light emitting device design featuring a substrate with first and second electrodes spaced apart, a bar-type LED with a length greater than its width, and an insulative support body between the substrate and the LED, which includes conductive contact layers for stable connection and an insulative support body to prevent deviation, using either a photo process or front vertical etching to form the support body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If bar-type LEDs are made small for pixel use, then they are suitable for micro-scale display panels, but they are prone to deviation during subsequent processes
Solution Approach 1:
An insulative support body is introduced as an intermediary element between the substrate and the bar-type LED. This support body provides mechanical stabilization and prevents deviation of the small LED during subsequent processing steps, resolving the contradiction between miniaturization and alignment stability.
Solution Approach 2:
The insulative support body is formed in advance before mounting the bar-type LED. This preliminary action creates a stable foundation that ensures proper positioning and prevents deviation during later processes, addressing the reliability issue associated with small LED sizes.
2Manufacturing precision
If bar-type LEDs are mounted precisely at desired positions, then pixel alignment is achieved, but subsequent processes may cause deviation
Solution Approach 1:
The insulative support body acts as a mediator that locks the bar-type LED in its precisely aligned position. It provides mechanical support that prevents position drift during subsequent processing, maintaining both the initial alignment precision and stability throughout manufacturing.
Solution Approach 2:
The support body provides beforehand cushioning by creating a stable mechanical environment that protects the precisely aligned LED from deviation during subsequent processes. This protective measure ensures that the manufacturing precision achieved during alignment is maintained throughout production.
3Area of stationary object
If electrodes are spaced closely for high-density pixels, then display resolution improves, but risk of short circuits increases
Solution Approach 1:
The insulative support body serves as an electrical insulator between the substrate and the bar-type LED, preventing short circuits even when electrodes are closely spaced. This allows for high-density pixel arrangements while maintaining electrical isolation and reducing the risk of harmful short circuit effects.
Solution Approach 2:
The insulative support body creates an electrically inert environment between conductive elements, preventing unwanted electrical interactions. This inert electrical environment enables closer electrode spacing for high-density displays while mitigating the harmful effect of short circuits.
Data Source
AI summary
A light emitting device including first and second electrodes spaced apart from each other on a substrate, at least one bar-type LED having a first end on the first electrode and a second end on the second electrode, and an insulative support body between the substrate and the bar-type LED. The at least one bar-type LED has a length greater than a width.