Graphene Separation Layer for Flat-End Light Emitting Elements
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Solution Overview
Problem
Inorganic light emitting diodes often have uneven end surfaces due to physical separation methods, leading to short circuit issues when contacting electrodes, which can cause open or short circuit problems.
Innovation Solution
A manufacturing method involving a substrate with a buffer material layer and a separating layer, including graphene, to form a light emitting element with a flat and parallel end surface by etching and peeling, ensuring a smooth parting surface and preventing electrode material short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a physical separation method is used to separate the light emitting element, then the manufacturing process is simple, but the end surface becomes uneven and jagged causing short circuit problems
Solution Approach 1:
A separating layer comprising at least one graphene layer is introduced as an intermediary between the lower substrate and the element deposition structure. This separating layer enables clean separation while maintaining a flat parting surface, resolving the contradiction between simple separation and surface flatness by mediating the separation process.
Solution Approach 2:
The interface attractive force between the separating layer and the lower substrate is made greater than the interface attractive force between the separating layer and the element rod. This parameter change in interfacial adhesion forces ensures the separating layer remains attached to the substrate during separation, providing a flat parting surface without requiring complex processing.
2Ease of operation
If the separating layer is strongly attached to the element rod, then separation is easy, but the parting surface becomes uneven
Solution Approach 1:
The interface attractive force between the separating layer and the lower substrate is engineered to be greater than the interface attractive force between the separating layer and the element rod. This parameter optimization allows the separating layer to remain attached to the substrate during separation, providing a flat parting surface while enabling easy separation of the element rod.
Solution Approach 2:
The separating layer acts as a mediator with controlled adhesion properties. By comprising at least one graphene layer, it provides a interface that facilitates easy separation from the element rod while maintaining strong attachment to the substrate, thus achieving both ease of operation and manufacturing precision.
3Productivity
If conventional separation methods are used, then productivity is high, but reliability decreases due to short circuit issues
Solution Approach 1:
The separating layer comprising at least one graphene layer serves as a mediator that enables high-productivity separation while ensuring reliable electrode contact. It provides a flat parting surface that prevents short circuits, thus maintaining both high manufacturing throughput and product reliability.
Solution Approach 2:
By optimizing the interface attractive forces at the separation interfaces, the method achieves clean separation with a flat parting surface. This parameter optimization prevents short circuit issues while maintaining efficient manufacturing processes, thereby improving reliability without sacrificing productivity.
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 produces light emitting elements with flat ends, preventing open or short circuit issues during electrode contact, enhancing the reliability of display devices by ensuring even contact surfaces.
Implementation Method 1
forming an element rod by etching the element deposition structure and the separating layer in a vertical direction
Implementation Method 2
separating the element rod from the lower substrate to form a light emitting element
Data Source
AI summary
Provided are a light-emitting element, a manufacturing method thereof, and a display device comprising the light-emitting element. The method for manufacturing the light-emitting element comprises the steps of: preparing a lower substrate including a substrate and a buffer material layer formed on the substrate, forming a separating layer disposed on the lower substrate and including at least one graphene layer, forming an element deposition structure by depositing a first conductivity type semiconductor layer, an active material layer, and a second conductivity type semiconductor layer on the separating layer, forming an element rod by etching the element deposition structure and the separating layer in a vertical direction; and separating the element rod from the lower substrate to form a light emitting element.