Grooved Insulating Layer for Reliable LED Positioning in Displays

Solution Overview

Problem

Current display devices face challenges in reducing manufacturing costs and improving reliability, particularly in the integration and positioning of light emitting elements within the device structure.

Innovation Solution

A display device design featuring a substrate with a first and second electrode, a groove-shaped insulating layer that houses a light emitting element, and additional electrodes for connection, along with a wavelength conversion layer and a fixed layer, which reduces manufacturing complexity and enhances element positioning reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate fixing members are used to secure light emitting elements, then positioning reliability is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvepositioning reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the fixing member and the insulating layer into a single integrated structure. The insulating layer is formed to protrude over the light emitting element, combining the electrical insulation function with the mechanical fixing function. This eliminates the need for separate fixing members while maintaining positioning reliability and reduces device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating layer serves multiple functions simultaneously: it provides electrical insulation between conductive elements and acts as a fixing structure that secures the light emitting element in position. This multi-functionality reduces the number of separate components needed and simplifies the overall device structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate fixing members are used to secure light emitting elements, then positioning reliability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvepositioning reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the fixing member and the insulating layer into a single integrated structure. The insulating layer is formed to protrude over the light emitting element, combining the electrical insulation function with the mechanical fixing function. This eliminates the need for separate fixing members while maintaining positioning reliability and reduces device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating layer serves multiple functions simultaneously: it provides electrical insulation between conductive elements and acts as a fixing structure that secures the light emitting element in position. This multi-functionality reduces the number of separate components needed and simplifies the overall device structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If light emitting elements are positioned on a flat insulating layer, then device complexity is reduced, but positioning reliability deteriorates

Engineering Contradiction:

Improvedevice complexityVSAvoidpositioning reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent transitions from a two-dimensional flat insulating layer to a three-dimensional protruding structure. The insulating layer extends vertically to form sides that overhang the light emitting element, creating a recessed positioning space. This dimensional change provides mechanical engagement and secure positioning without requiring additional fixing components.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The light emitting element is nested within the recessed space formed by the protruding insulating layer. The insulating layer's sides extend over the element, creating a nested configuration that secures the element in position through geometric constraint rather than additional fastening mechanisms.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 lowers manufacturing costs by eliminating the need for separate fixing members and improves reliability by securely positioning light emitting elements within the device, enhancing overall display performance.

Implementation Method 1

the insulating material layer reflows, and a portion of the light emitting element is buried in and fixed to the insulating material layer

Methodology Applied

Scientific EffectReflow:

Data Source

PatentUS11871598B2Display device and method of manufacturing thereof

Publication Date: 2024.01.09 SAMSUNG DISPLAY CO LTD

AI summary

A display device and a manufacturing method thereof are provided. A display device includes: a substrate; a first electrode and a second electrode on the substrate, the first electrode and the second electrode being arranged on a same layer to be spaced apart from each other; a first insulating layer on the first electrode and the second electrode; and a light emitting element on the first insulating layer. The first insulating layer includes a groove concave toward the substrate, and the light emitting element is in the groove.