Flexible Ultra-Thin LED Skin Patch for Self-Aligned Manufacturing
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Solution Overview
Problem
Existing nanorod-type LEDs face challenges in manufacturing due to their large aspect ratio, which leads to precipitation issues in solvents, limited inkjet printing capabilities, and low emission efficiency, as well as complex electrode design and assembly difficulties, especially for micro- and nano-LEDs.
Innovation Solution
A flexible ultra-thin LED skin patch is developed with an LED electrode assembly featuring a dot-type, disk-type, or micro-nanofin LED device structure, where the LED devices are stacked with a conductive semiconductor layer, photoactive layer, and another semiconductor layer, and are self-aligned using magnetic or charge layers, allowing for easier assembly and improved light emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If nanorod-type LED devices with large aspect ratio are used for alignment through electric field, then self-alignment capability is improved, but inkjet printing capability deteriorates due to precipitation in solvent
Solution Approach 1:
The patent changes the geometric parameters of the LED device from nanorod shape with large aspect ratio to nanodot or nanodisk shape with small aspect ratio. This parameter change allows the LED devices to remain suspended in solvent without precipitation, enabling inkjet printing while still allowing for electric field-based self-alignment during the manufacturing process
2Ease of manufacture
If nanorod-type LED devices are assembled by laying on two different electrodes, then assembly is achieved, but light extraction efficiency deteriorates due to small emitting area
Solution Approach 1:
The patent transitions from assembling nanorod-type LEDs in a horizontal plane between two electrodes to assembling nanodot/nanodisk-type LEDs in a vertical stacking configuration. This dimensional change allows the emitting surface to face upward, significantly increasing the light extraction area and efficiency while simplifying the assembly process to a single electrode substrate
3Manufacturing precision
If micro-LEDs are individually placed on miniaturized electrodes using pick and place technology, then high resolution display is achieved, but manufacturing cost increases and productivity decreases
Solution Approach 1:
The patent employs self-alignment mechanisms where nanodot/nanodisk LED devices automatically position themselves onto electrode patterns through electric field effects during the inkjet printing process. This self-service approach eliminates the need for complex pick-and-place operations, significantly improving manufacturing efficiency and productivity while maintaining high display resolution
Solution Approach 2:
The patent replaces the mechanical pick-and-place system with an inkjet printing system that deposits LED devices in solution, followed by electric field-based self-alignment. This substitution eliminates mechanical handling complexities, reduces manufacturing costs, and improves productivity while achieving the required precision for high-resolution displays
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 solution enables the production of high-efficiency, flexible LED skin patches that can be easily manufactured and applied to the skin, effectively treating or improving skin conditions by emitting specific wavelengths of light, while overcoming previous manufacturing and efficiency limitations.
Implementation Method 1
an ultra-thin LED device in which a first conductive semiconductor layer, a photoactive layer, and a second conductive semiconductor layer are stacked, the ultra-thin LED device includes an LED device that emits UV of a wavelength of 200 to 400 nm
Implementation Method 2
the LED devices are stacked with a conductive semiconductor layer, photoactive layer, and another semiconductor layer, and are self-aligned using magnetic or charge layers
Implementation Method 3
as the LED devices are aligned through an electric field, the LED devices must have a rod shape with a large aspect ratio
Data Source
AI summary
The present invention relates to a flexible skin patch equipped with an ultra-thin LED assembly that emits light in a specific wavelength range and an invention for manufacturing the same, and is related to an invention capable of providing a flexible skin patch that has the excellent effect of promoting vitamin D production in a localized area of the skin, and has the effect of alleviating or treating local skin psoriasis, fungi, fungal tumors and eczema, and has excellent antiviral effect, and is easy to attach and detach.