Electrode Segmentation for Light Emitting Element Alignment
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Solution Overview
Problem
Existing display devices face challenges in reducing the number of lost light emitting elements during manufacturing and improving the alignment of light emitting elements, particularly due to variations in electrode thickness and structure.
Innovation Solution
The display device incorporates electrodes with varying thicknesses and structures, featuring main electrode portions and sub-electrode portions with different thicknesses, which are integrated and connected to guide light emitting elements effectively, reducing losses and enhancing alignment through controlled electric fields and ink flow during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrodes have uniform thickness, then manufacturing process is simpler, but light emitting elements have poor alignment and higher loss rate
Solution Approach 1:
The electrode is divided into multiple segments with different thicknesses: a first electrode portion with greater thickness and a second electrode portion with lesser thickness. This segmentation allows the electrode to provide both strong electric field regions (thinner portions) for precise light emitting element alignment and structural support (thicker portions), thereby improving alignment precision while managing manufacturing complexity
Solution Approach 2:
Different portions of the electrode are given different thicknesses to perform different functions. The first electrode portion has greater thickness for structural stability and connection, while the second electrode portion has lesser thickness to create specific electric field patterns that guide light emitting element alignment. This local differentiation resolves the contradiction by optimizing each region for its specific purpose
2Reliability
If electrodes have varying thicknesses, then alignment of light emitting elements improves, but manufacturing complexity increases
Solution Approach 1:
The electrode structure with varying thicknesses is prepared in advance during the manufacturing process. The first and second electrode portions are formed with predetermined thickness differences before light emitting element placement. This preliminary structuring creates built-in alignment guides that improve reliability by reducing lost elements, while the thickness variation is achieved through standard manufacturing techniques to minimize fabrication complexity
3Strength
If electrode thickness is increased, then structural strength improves, but alignment precision of light emitting elements deteriorates
Solution Approach 1:
The electrode is segmented into a first portion with greater thickness for structural strength and a second portion with lesser thickness for alignment precision. This segmentation allows the electrode to simultaneously provide mechanical robustness where needed and precise electric field patterns where light emitting elements are placed, resolving the contradiction between strength and precision
Solution Approach 2:
The electrode structure implements local quality differentiation where the first electrode portion has increased thickness for strength and the second electrode portion has reduced thickness for precision alignment. Each local region is optimized for its specific function, allowing the overall electrode to satisfy both structural and precision requirements
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 reduces the number of lost light emitting elements and improves their alignment, leading to increased luminous efficiency and reduced defective rates per sub-pixel, while allowing for precise placement of light emitting elements on the electrodes.
Implementation Method 1
improving a degree of alignment of the light emitting elements
Data Source
AI summary
A display device includes a first electrode and a second electrode extending in one direction on a substrate and spaced from each other, a first insulating layer on the first electrode and the second electrode, and a plurality of light emitting elements located on the first electrode and the second electrode, the plurality of light emitting elements being on the first insulating layer, wherein each of the first electrode and the second electrode includes a main electrode portion and a plurality of sub-electrode portions having a thickness smaller than that of the main electrode portion, the plurality of sub-electrode portions of each of the first electrode and the second electrode are connected to respective sides of the main electrode portion of the corresponding ones of the first electrode and the second electrode in the one direction.