Bar-Type LED Alignment in Cavity Metal Member for Luminance Uniformity
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Solution Overview
Problem
Existing light emitting devices using bar-type LEDs face challenges in achieving uniform luminance characteristics due to variations in the number and arrangement of LEDs within pixel regions, leading to non-uniform brightness.
Innovation Solution
A light emitting device design featuring a substrate with a metal member having cavities that accommodate bar-type LEDs, where the LEDs are electrically connected through a first and second electrode, with a connecting member and insulating layers to ensure uniform alignment and electrical contact, and a fabricating method that includes forming a metal member with isotropic etching and inclined insulating layers to stabilize LED placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If bar-type LEDs are arranged in pixel regions without specific structural constraints, then the device complexity is reduced, but the luminance uniformity deteriorates due to variations in LED arrangement
Solution Approach 1:
The pixel region is divided into multiple cavities, with each cavity accommodating a specific number of bar-type LEDs. This segmentation ensures uniform distribution of light-emitting elements across the pixel region, resolving the luminance uniformity issue while maintaining manageable structural complexity.
Solution Approach 2:
Each cavity is designed with specific local characteristics (size, shape, position) to accommodate a predetermined number of LEDs. This local optimization ensures that each region contributes uniformly to the overall luminance, solving the uniformity problem without requiring complex global restructuring.
2Illumination intensity
If a metal member with cavities is introduced to accommodate bar-type LEDs, then the luminance uniformity is improved through consistent alignment, but the device complexity increases
Solution Approach 1:
The metal member serves multiple functions simultaneously: it provides structural support, defines cavity positions for LED alignment, and acts as an electrical connection substrate. This multi-functionality achieves luminance uniformity through consistent alignment while minimizing the increase in device complexity by consolidating multiple functions into a single component.
3Productivity
If the cavity width is increased to accommodate multiple bar-type LEDs, then the productivity is improved by allowing more LEDs per pixel region, but the manufacturing precision may deteriorate
Solution Approach 1:
Rather than creating one large cavity, the structure divides the space into multiple smaller cavities within the pixel region. Each cavity is precisely formed to accommodate a specific number of LEDs, maintaining manufacturing precision while increasing overall LED density and productivity.
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 solution achieves uniform or substantially uniform luminance characteristics across pixel regions by ensuring consistent alignment and electrical connection of bar-type LEDs, enhancing the overall brightness and performance of light emitting devices.
Implementation Method 1
a metal member on the first electrode and having an cavity; a first insulating layer on the metal member and exposing the cavity therethrough; a bar-type LED having a first end portion and a second end portion; The first end portion of the bar-type LED is in the cavity
Implementation Method 2
a connecting member between the first end portion of the bar-type LED in the cavity and the first electrode
Implementation Method 3
a first insulating layer on the metal member and exposing the cavity therethrough; a second insulating layer between the first insulating layer and the second electrode
Data Source
AI summary
A light emitting device includes: a substrate; a first electrode on the substrate; a metal member on the first electrode and having a cavity; a first insulating layer on the metal member and exposing the cavity therethrough; a bar-type LED having a first end portion and a second end portion; and a second electrode on the first insulating layer. The first end portion of the bar-type LED is in the cavity and electrically connected to the first electrode, and the second end portion of the bar-type LED protrudes outside of the cavity and is electrically connected to the second electrode.