Groove-Based Reflective Layer for LED Luminous Efficiency
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Solution Overview
Problem
Current display devices face challenges in achieving high luminous efficiency, particularly in the manufacturing of ultra-small rod-shaped LEDs used in self-luminous display devices, where existing techniques struggle to optimize the arrangement and alignment of electrodes and reflective layers for effective light emission.
Innovation Solution
A display device design featuring an insulation layer with a groove, a first reflective layer overlapping the light emitting element, and electrodes extending in specific directions with a narrow gap, along with a manufacturing method that includes forming electrodes and a reflective layer on the groove, filling the groove with insulation material, and aligning the light emitting element between the electrodes using an alignment signal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional flat structure is used for electrodes and reflective layers, then the manufacturing process is simple, but the luminous efficiency is insufficient due to poor light emission directionality
Solution Approach 1:
The patent introduces a groove structure that adds vertical dimensionality to the otherwise planar electrode and reflective layer configuration. The groove creates a three-dimensional arrangement where the reflective layer is positioned at the bottom and sides of the groove, enabling light to be reflected from multiple angles and directed toward the light-emitting element from below, thereby improving luminous efficiency without significantly complicating the manufacturing process
Solution Approach 2:
The reflective layer is selectively positioned within the groove structure rather than being uniformly distributed across the entire substrate. This localized placement of the reflective layer directly beneath and around the light-emitting element ensures that reflection occurs precisely where needed to enhance light emission, avoiding unnecessary material usage and maintaining manufacturing simplicity
2Loss of energy
If the distance between electrodes is large, then the alignment process is easier, but the light emission directionality and luminous efficiency are reduced
Solution Approach 1:
The groove structure is formed beforehand in the insulation layer before the electrodes and light-emitting elements are positioned. This pre-formed groove serves as a physical guide and alignment reference that ensures the light-emitting element is correctly positioned relative to the electrodes and reflective layer, enabling precise alignment even when the electrode spacing is minimized for optimal luminous efficiency
3Area of moving object
If ultra-small rod-shaped LEDs are used to reduce pixel size, then the display device can achieve higher resolution, but the alignment and arrangement of these微小 components becomes increasingly difficult
Solution Approach 1:
The light-emitting element is nested within the groove structure, which itself is embedded in the insulation layer. The electrodes are positioned on either side of the groove, creating a nested arrangement where each component is precisely positioned relative to the others. This nested configuration ensures that even ultra-small rod-shaped LEDs are correctly aligned with the reflective layer and electrodes, maintaining manufacturing precision despite the small component size
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 enhances luminous efficiency by ensuring effective light emission directionality and alignment, improving the manufacturing process for display devices with ultra-small LEDs, resulting in improved performance and efficiency.
Implementation Method 1
a first reflective layer on at least a portion of the insulation layer... overlapping at least a portion of the groove
Data Source
AI summary
A display device according to an exemplary embodiment of the present disclosure comprises an insulation layer on a substrate and having a groove concave in a direction toward the substrate; a first reflective layer on at least a portion of the insulation layer; and a display element layer on the insulation layer and the first reflective layer, the display element layer including a light emitting element overlapping at least a portion of the groove.