LED Chip Manufacturing With Random Mixing for Mura Reduction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The manufacturing process of LED chips often results in uneven properties among the chips, leading to defects such as the mura phenomenon due to variations in manufacturing processes, positions, or parameters, which affects their performance and image quality in displays.

Innovation Solution

A method involving the random mixing of LED elements with epitaxial structures before performing a mesa process and forming electrodes, which helps in distributing the elements evenly and reducing defects by mixing them before subsequent processes like mesa formation and electrode creation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If LED elements are manufactured using conventional processes without random mixing, then the manufacturing process is simple and straightforward, but the LED chips exhibit uneven properties leading to defects such as mura phenomenon

Engineering Contradiction:

Improveuniformity of LED chip propertiesVSAvoidcomplexity of manufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by performing random mixing of LED elements before the mesa process and electrode formation. This preliminary mixing step ensures uniform distribution of LED elements with different properties, preventing mura phenomenon in the final display while maintaining a relatively simple manufacturing process.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If LED elements are randomly mixed before mesa process, then the uniformity of LED chip properties is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveuniformity of LED chip propertiesVSAvoidease of manufacturing process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The random mixing is performed as a preliminary action before the mesa process, which simplifies subsequent manufacturing steps. By pre-distributing LED elements uniformly, the patent avoids the need for complex sorting or selection processes later, making the overall manufacturing easier despite the added mixing step.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If LED elements are not randomly mixed, then the manufacturing process is easier to implement, but defects such as mura phenomenon appear in the display

Engineering Contradiction:

Improvequality of display imageVSAvoidcomplexity of mixing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements random mixing as a preliminary action to ensure uniform distribution of LED elements before they are processed into chips. This preliminary mixing step significantly improves display quality by preventing mura phenomenon, while the mixing process itself remains relatively simple and can be integrated into existing manufacturing lines.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11742457B2Electronic device and manufacturing method thereof

Publication Date: 2023.08.29 INNOLUX CORP

AI summary

The disclosure discloses a method for manufacturing light-emitting diode (LED) chips. The manufacturing method includes: providing a plurality of LED elements; randomly mixing the plurality of LED elements; performing a mesa process on the plurality of LED elements; and forming at least one pair of electrodes on the plurality of LED elements. An electronic device includes the LED chips.