Bar-Type LED Integration With Insulating Protrusions
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Solution Overview
Problem
Existing light emitting devices face challenges in efficiently integrating micro or nano-scale bar-type LEDs with inorganic crystal structures, particularly in creating a stable and efficient light emitting configuration that minimizes short circuits and maximizes lifespan and luminance.
Innovation Solution
A light emitting device design featuring a substrate with a first electrode, an insulating layer with protruding parts and holes, and a second electrode, where bar-type LEDs are positioned within the holes, allowing for vertical or oblique orientation and connection to the electrodes, along with a method of forming conductive layers and applying an electric field for self-alignment and light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bar-type LEDs are densely arranged on the substrate, then productivity and luminance are improved, but the risk of short circuits between adjacent LEDs increases
Solution Approach 1:
The substrate surface is segmented into multiple isolation regions by insulating structures (protruding parts or grooves). Each isolation region contains one or more bar-type LEDs, physically separating them to prevent short circuits while allowing dense arrangement. The insulating structures divide the continuous substrate into discrete zones, enabling high-density packaging without compromising electrical isolation between adjacent LEDs.
2Productivity
If micro or nano-scale bar-type LEDs with inorganic crystal structures are integrated, then device miniaturization and productivity are improved, but manufacturing precision and alignment difficulty increase
Solution Approach 1:
Isolation structures (protruding parts or grooves) are formed on the substrate before the bar-type LEDs are placed or grown. These pre-formed structures serve as alignment guides and positioning features, enabling precise placement of micro/nano-scale LEDs during subsequent manufacturing steps. The preliminary formation of isolation regions establishes a reference framework that simplifies alignment and positioning of subsequent components.
Solution Approach 2:
The insulating protruding parts or grooves act as intermediary structures between the substrate and the bar-type LEDs. These intermediaries provide mechanical support, electrical isolation, and alignment references simultaneously. The protruding parts serve as physical guides that facilitate precise positioning of the small-scale LEDs, while the grooves provide similar functions through their geometric constraints.
3Reliability
If insulating structures with protruding parts are formed to prevent short circuits, then reliability is improved, but device complexity and fabrication steps increase
Solution Approach 1:
The isolation structures serve multiple functions simultaneously: they provide electrical insulation between adjacent LEDs, act as mechanical support structures, serve as alignment guides during fabrication, and define the spatial arrangement of LEDs. By combining these multiple functions into a single structural element, the patent reduces overall device complexity despite the added reliability feature.
Solution Approach 2:
The insulating protruding parts or grooves are designed as universal structures that perform multiple roles in the device architecture. They provide electrical isolation, mechanical support, alignment reference, and spatial organization all through the same structural feature. This multi-functionality reduces the need for separate components for each function, thereby managing fabrication complexity while maintaining high reliability.
4Illumination intensity
If bar-type LEDs are oriented vertically or obliquely relative to the substrate surface, then light emission efficiency and luminance are improved, but manufacturing difficulty and alignment precision requirements increase
Solution Approach 1:
The isolation structures are designed with asymmetric geometries (protruding parts with specific shapes or grooves with particular orientations) that guide the bar-type LEDs into vertical or oblique orientations. The asymmetric features of the isolation structures create preferential directions for LED placement and growth, naturally inducing the desired orientation without requiring complex external alignment mechanisms during fabrication.
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 configuration enhances the light emitting device's efficiency, lifespan, and luminance by preventing short circuits and allowing for dense LED arrangement, while enabling easy fabrication and alignment of bar-type LEDs for improved performance in display and lighting applications.
Implementation Method 1
applying an electric field between the first and second electrodes; and scattering bar-type LEDs on the substrate. Forming the electric field and scattering the bar-type LEDs may be simultaneously performed.
Data Source
AI summary
A light emitting device includes a first electrode, an insulating layer, a second electrode, and a bar-type light emitting diode (LED). The insulating layer includes a plurality of protruding parts protruding from the first electrode and at least one hole between the protruding parts. The second electrode on the insulating layer. The bar-type LED is in the at least one hole. The bar-type LED has a first end and a second end in the length direction. One of the first or second ends is connected to the first electrode and the other of the first or second ends is connected to the second electrode.