Electrostatic LED Self-Alignment Using Bank Conductive Patterns
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Solution Overview
Problem
Existing display devices face challenges in easily self-aligning LEDs, which complicates the manufacturing process and increases costs due to the need for precise alignment and longer processing times.
Innovation Solution
A display device design that includes a substrate with thin film transistors, planarization layers, electrodes, and conductive patterns on a bank, allowing LEDs to be self-aligned by applying voltage to the conductive patterns, facilitating their precise placement and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional LED placement methods are used, then manufacturing precision can be maintained, but device complexity and processing time increase
Solution Approach 1:
The patent implements self-alignment of LEDs using electrostatic forces generated by conductive patterns on the bank. The LEDs automatically align themselves to the correct positions through electrical attraction without requiring complex external alignment mechanisms or manual positioning, thus maintaining high manufacturing precision while reducing process complexity
Solution Approach 2:
The patent replaces mechanical alignment methods with electrical field-based alignment. Instead of using physical guides, mechanical fixtures, or complex positioning mechanisms, the invention uses conductive patterns that generate electrostatic forces to guide and position LEDs automatically, simplifying the manufacturing process while maintaining precision
2Manufacturing precision
If conventional LED placement methods are used, then alignment accuracy can be achieved, but processing time increases
Solution Approach 1:
The self-alignment mechanism allows LEDs to automatically position themselves through electrostatic attraction to the conductive patterns. This eliminates time-consuming manual alignment steps and enables parallel processing of multiple LEDs simultaneously, significantly reducing total processing time while maintaining alignment accuracy
Solution Approach 2:
The conductive patterns are pre-configured on the bank before LED placement. This preliminary preparation creates ready-to-use alignment fields that guide LEDs into correct positions immediately upon contact, eliminating the need for time-consuming alignment adjustments during the placement process
3Adaptability or versatility
If additional conductive patterns are added for touch sensing, then functionality is enhanced, but device complexity increases
Solution Approach 1:
The conductive patterns on the bank serve dual purposes: they provide electrostatic alignment forces for LED positioning and simultaneously function as touch sensing electrodes. This multi-functionality allows the same structural elements to perform both manufacturing and user interaction functions, enhancing versatility without proportionally increasing complexity
Solution Approach 2:
The patent merges the alignment function and touch sensing function into a single integrated system. The conductive patterns that guide LED placement are combined with touch electrode functionality, creating a unified structure that performs both manufacturing assistance and user interaction tasks
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 method enables efficient self-alignment of LEDs, reduces processing time and costs, and allows for the integration of a touch sensing part using additional conductive patterns, enhancing the reliability and functionality of the display device.
Implementation Method 1
facilitating self-alignment of a plurality of LEDs by applying a voltage to the plurality of first conductive patterns
Data Source
AI summary
A display device includes a substrate including a plurality of sub-pixels, a plurality of thin film transistors disposed on the substrate, a planarization layer disposed on the plurality of thin film transistors, a plurality of first electrodes disposed on the planarization layer and electrically connected to the plurality of thin film transistors, a plurality of second electrodes disposed on the planarization layer and spaced apart from the plurality of first electrodes, a bank covering a part of each of the plurality of first electrodes and the plurality of second electrodes and disposed to define an emission area, a plurality of LEDs disposed in the emission area and electrically connected to the plurality of first electrodes and the plurality of second electrodes and a plurality of first conductive patterns disposed on the bank. Therefore, self-alignment of the LEDs can be easily achieved.