Display Element Alignment Using Groove Molds and Electric Fields
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Solution Overview
Problem
Current display device manufacturing methods face challenges in achieving precise alignment of light emitting elements, leading to inefficiencies in light emission and potential short circuits due to random arrangement and agglomeration of these elements.
Innovation Solution
A manufacturing method and apparatus that utilize a mold with groove patterns to align light emitting elements by applying pressure, using a combination of mechanical and electric field alignment techniques, ensuring accurate positioning and reducing agglomeration, while a cleaner maintains the mold's surface integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light emitting elements are deposited using ink without alignment structures, then the manufacturing process is simple, but the alignment degree of light emitting elements is poor leading to random arrangement and agglomeration
Solution Approach 1:
A mold with groove patterns is introduced as an intermediary tool between the ink deposition and the substrate. The mold receives the ink containing light emitting elements, allows them to be deposited in organized grooves, and then releases them onto the substrate in aligned positions, eliminating random arrangement while keeping the ink-based deposition method
Solution Approach 2:
The mold is divided into multiple groove patterns that segment the deposition area into distinct alignment zones. Each groove acts as a separate channel guiding light emitting elements to specific positions, transforming the random deposition into organized, segmented placement across the substrate surface
2Productivity
If light emitting elements are randomly arranged, then the manufacturing process is fast, but light emission efficiency decreases due to agglomeration and misalignment
Solution Approach 1:
The mold with groove patterns is prepared in advance to define the desired alignment positions before ink deposition. The grooves are pre-formed structures that automatically guide light emitting elements to correct positions during deposition, ensuring alignment is built-in from the start rather than requiring post-processing adjustment
3Manufacturing precision
If a mold with groove patterns is used to align light emitting elements, then alignment degree improves, but device complexity increases due to additional components
Solution Approach 1:
The mold serves multiple functions simultaneously: it acts as a deposition template for organizing light emitting elements, a transfer medium for moving elements from ink to substrate, and an alignment guide through its groove patterns. This multi-functionality reduces the need for separate alignment tools and simplifies the overall manufacturing system
4Manufacturing precision
If mechanical pressure is applied through a press on the mold, then light emitting elements are better aligned, but the risk of damaging elements increases
Solution Approach 1:
The mold is constructed with flexible or compliant material that can deform under pressure from the press. This flexibility allows the mold to apply gentle, distributed pressure to guide light emitting elements into grooves without concentrating excessive force on individual elements, thereby achieving alignment while minimizing damage risk
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 method significantly improves the alignment degree of light emitting elements, enhancing light emission efficiency and preventing unwanted short circuits, thereby improving the overall performance and reliability of display devices.
Implementation Method 1
allowing the mold to apply a pressure to the light emitting elements
Implementation Method 2
forming an electric field by using the alignment electrode. The light emitting elements may be aligned based on the electric field
Data Source
AI summary
A method of manufacturing a display device, a display device, and an apparatus for manufacturing a display device are provided. A method of manufacturing a display device includes: providing an ink including light emitting elements on a manufacturing substrate; and aligning the light emitting elements by using a mold including a plurality of groove patterns.