Inclined Display Electrodes for Self-Aligned Nano-LED Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display technologies face challenges in efficiently aligning and connecting nano-sized light-emitting devices (LEDs) to electrodes due to the difficulty in precise positioning and contact, leading to potential contact failures and reduced alignment efficiency.
Innovation Solution
A display apparatus design featuring electrodes with inclined surfaces and a method of manufacturing that includes forming conductive layers, patterning electrodes with masks having variable light transmittance, and applying light-emitting devices using a solvent under controlled electric polarities to achieve self-alignment and improved contact between LEDs and electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional flat electrodes are used to connect nano-sized LEDs, then the manufacturing process is simple, but the alignment precision and contact reliability are poor
Solution Approach 1:
The electrode structure incorporates inclined surfaces that protrude from the flat upper surface, creating a curved/angled geometry instead of a purely flat surface. This curvature enables better mechanical interlocking and alignment with the nano-sized LED components, thereby improving alignment precision and contact reliability while maintaining manufacturing feasibility through standard photolithography and etching processes.
2Productivity
If the distance between electrodes is reduced to improve connection efficiency, then contact efficiency increases, but the risk of contact failure increases due to positioning difficulty
Solution Approach 1:
The inclined surfaces create a tapered geometry that guides the nano-sized LEDs into proper contact positions. Even when electrode spacing is reduced to improve connection efficiency, the angled surfaces provide mechanical guidance that prevents misalignment and contact failure, thereby maintaining both high productivity and reliability.
Solution Approach 2:
The inclined electrode surfaces enable self-alignment of the nano-sized LEDs during the assembly process. The geometry itself provides the alignment function, eliminating the need for additional complex alignment mechanisms or processes, thus improving connection efficiency without compromising reliability.
3Manufacturing precision
If inclined surfaces are added to electrodes to improve alignment, then alignment efficiency improves, but the manufacturing process becomes more complex
Solution Approach 1:
The inclined surfaces are formed using standard semiconductor manufacturing techniques such as photolithography with angled masks or reactive ion etching with controlled geometry. These are conventional processes in the display industry, so while they add some complexity compared to flat electrodes, they remain within the capabilities of existing manufacturing lines without requiring entirely new process equipment.
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 the self-alignment and contact efficiency of LEDs on the electrodes, reducing alignment errors and increasing light extraction efficiency and luminescent intensity by ensuring proper positioning and connection.
Implementation Method 1
aligning the plurality of light-emitting devices by assigning different electric polarities to the first electrode and the second electrode so that two ends of each of the plurality of light-emitting devices respectively contact the upper surfaces of the first portions of the first electrode and the second electrode
Data Source
AI summary
A display apparatus includes a substrate, a first electrode on the substrate, the first electrode including a first portion that has a flat upper surface and a second portion that protrudes from the first portion and has an inclined surface, a second electrode facing the first electrode in parallel on the substrate, the second electrode including a first portion that has a flat upper surface and a second portion that protrudes from the first portion and has an inclined surface, and a plurality of light-emitting devices separate from each other on the first electrode and the second electrode, the light-emitting devices each having a first end contacting the upper surface of the first portion of the first electrode and a second end contacting the upper surface of the first portion of the second electrode.