Display Electrode Layout With Guide Patterns for LED Alignment
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Solution Overview
Problem
Existing display devices face issues with light-emitting elements being misplaced during fabrication, leading to a significant number of failed connections with electrodes and misalignment, resulting in inefficiencies.
Innovation Solution
The introduction of patterns between banks on which electrodes are arranged, creating height differences to guide light-emitting elements into precise placement between these patterns, ensuring both ends of the elements are correctly positioned on the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light-emitting elements are placed during fabrication without guidance structures, then the fabrication process is simpler, but the alignment precision of light-emitting elements on electrodes deteriorates
Solution Approach 1:
The patent introduces patterns as intermediary structures between the banks and light-emitting elements. These patterns serve as guide structures that facilitate precise placement of light-emitting elements on electrodes during fabrication, resolving the contradiction by adding a mediating component rather than directly modifying the light-emitting elements or electrodes themselves.
Solution Approach 2:
The patterns are formed in advance during the fabrication process before the light-emitting elements are placed. This preliminary action creates the guidance structure needed for subsequent precise placement, allowing the alignment precision to be improved without complicating the actual placement operation.
2Reliability
If light-emitting elements are arranged without spacing patterns, then the device structure is simpler, but the number of lost light-emitting elements increases
Solution Approach 1:
The patterns act as intermediary guide structures that define the precise locations where light-emitting elements should be placed. This intermediary structure ensures that elements are correctly positioned on electrodes, improving connection reliability while the pattern complexity remains manageable through systematic design.
Solution Approach 2:
The patterns are strategically placed only in specific locations where guidance is needed, rather than uniformly across the entire device. This local application of patterns provides the necessary reliability improvement while minimizing the overall structural complexity added to the device.
3Manufacturing precision
If more patterns are added to guide light-emitting elements, then the alignment improves, but the manufacturing complexity increases
Solution Approach 1:
The guidance structure is segmented into multiple discrete patterns rather than using a single complex structure. Each pattern independently guides light-emitting elements to specific electrode locations, allowing the system to achieve high placement precision through multiple simple, manageable components that can be manufactured and positioned separately.
Data Source
AI summary
A display device comprises a plurality of first banks disposed on a substrate to extend in a first direction and spaced apart from one another, a plurality of first patterns disposed between the plurality of first banks and spaced apart from one another in the first direction, a first electrode and a second electrode extending in the first direction and disposed on different first banks of the plurality of first banks and spaced apart from each other, a first insulating layer overlapping the plurality of first patterns, disposed on the first substrate, and to partially overlapping the first and second electrodes, and a plurality of light-emitting elements disposed on the first insulating layer so that first and second ends of each of the plurality of light-emitting elements are disposed on the first and second electrodes, respectively.