Bar-Type LED Structure for Precise Alignment and Short-Circuit Prevention
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Solution Overview
Problem
Existing technologies face challenges in fabricating micro-bar-type LEDs that maintain precise alignment during subsequent processes, leading to potential deviations and increased risk of short circuits, which affect the lifespan and efficiency of light emitting devices.
Innovation Solution
The use of a bar-type LED structure with an insulating film surrounding its outer circumferential surfaces, combined with an insulative support body to stabilize the LED's position, and conductive contact layers for stable electrical connections, ensures precise alignment and prevents short circuits, enhancing the lifespan and efficiency of the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bar-type LED is aligned at a desired position and mounted, then precise alignment is achieved, but the LED may deviate during subsequent processes
Solution Approach 1:
The insulative support body is formed in advance at the desired position before mounting the bar-type LED. This preliminary preparation creates a stable foundation that maintains alignment precision throughout subsequent manufacturing processes, preventing deviation without requiring continuous adjustment.
Solution Approach 2:
The insulative support body acts as an intermediary element between the substrate and the bar-type LED. It provides mechanical support and position stabilization, ensuring that the LED maintains its aligned position during handling and subsequent processing steps.
2Ease of manufacture
If bar-type LED is mounted on substrate, then device assembly is completed, but risk of short circuits increases
Solution Approach 1:
The insulative support body serves as an intermediary that electrically isolates the bar-type LED from the substrate. This mediation prevents direct electrical contact that could cause short circuits, while still providing mechanical support for easy assembly.
Solution Approach 2:
The insulative support body provides localized electrical insulation precisely where the bar-type LED contacts the substrate. This targeted approach addresses the short circuit risk at the critical interface without requiring insulating measures throughout the entire device structure.
3Stability of the object's composition
If insulative support body is formed, then position stability is improved, but device complexity increases
Solution Approach 1:
The insulative support body performs multiple functions simultaneously: it provides mechanical support for position stability, electrical insulation to prevent short circuits, and alignment reference during mounting. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity.
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
This approach improves the yield and reliability of light emitting devices by maintaining precise alignment and reducing the risk of short circuits, thereby extending the lifespan and improving efficiency.
Implementation Method 1
forming an insulative support body between the substrate and the bar-type LED... preventing bar-type LED deviation during fabrication
Implementation Method 2
conductive contact layers respectively connecting ends of the bar-type LED to the first and second electrodes
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A light emitting device includes 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.