LED Connection Structure With Protective Necked Joint for Display Yield
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Solution Overview
Problem
The challenge in improving the yield of electrical connections between Light-Emitting Diodes (LEDs) and substrates for enhanced display resolution lies in the inefficiencies in the connection structure and manufacturing process, particularly in achieving reliable and durable connections that withstand environmental factors.
Innovation Solution
A light-emitting device with a specific connection structure featuring a first electrical connection portion with an upper, lower, and neck portion, where the edges of the upper and lower portions are protruded, and a protective portion surrounding the contact electrode, utilizing conductive materials like gold and tin for enhanced conductivity and durability, and a method of manufacturing involving the use of thermosetting polymers and thermal curing to form the connection structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection structures are used for LED electrical connections, then the manufacturing process is simple, but the reliability and durability of connections under environmental factors deteriorates
Solution Approach 1:
The connection structure is divided into distinct functional segments: a first connection portion for electrical connection, a second connection portion for structural support, and a protective portion for environmental protection. This segmentation allows each part to optimize its specific function while maintaining overall reliability without excessive complexity.
Solution Approach 2:
The connection structure utilizes composite material composition with conductive materials (gold, tin) combined with protective materials forming different portions. This composite approach enhances both electrical conductivity and environmental resistance, improving reliability while the integrated design prevents excessive complexity.
2Productivity
If conventional electrical connection methods are used, then the manufacturing process is straightforward, but the yield and durability of LED connections deteriorates
Solution Approach 1:
The connection structure is designed with pre-formed first and second connection portions that are prepared in advance on the substrate before LED mounting. This preliminary action ensures proper alignment and connection geometry are established beforehand, improving manufacturing yield while the standardized design maintains ease of manufacture.
Solution Approach 2:
The connection structure employs specific geometric parameters including protruding edges at the first connection portion and a neck portion with controlled dimensions. These parameter optimizations enhance connection reliability and manufacturing yield while the parameters are designed to be achievable through standard manufacturing processes.
3Object-affected harmful factors
If simple connection structures are used, then the manufacturing process is easy, but the resistance to environmental factors like moisture and high temperatures deteriorates
Solution Approach 1:
The protective portion is extracted as a separate functional element from the connection structure, specifically designed to shield the first and second connection portions from environmental factors. This extraction provides targeted environmental protection without requiring complete redesign of the entire connection system, maintaining reasonable complexity.
Solution Approach 2:
The protective portion is designed in advance to cover and protect the electrical connection portions from moisture, high temperatures, and other environmental harmful factors. This beforehand cushioning approach ensures environmental resistance is built into the structure proactively rather than requiring complex reactive protection systems.
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 provides a robust and efficient electrical connection that improves the reliability and longevity of LED connections, enhancing display resolution and resistance to environmental factors like moisture and high temperatures.
Implementation Method 1
utilizing conductive materials like gold and tin for enhanced conductivity and durability, and a method of manufacturing involving the use of thermosetting polymers and thermal curing to form the connection structures
Data Source
AI summary
A light-emitting device includes a carrier, a light-emitting element and a connection structure. The carrier includes a first electrical conduction portion. The light-emitting element includes a first light-emitting layer capable of emitting first light and a first contact electrode formed under the light-emitting layer. The first contact electrode is corresponded to the first electrical conduction portion. The connection structure includes a first electrical connection portion and a protective portion surrounding the first contact electrode and the first electrical connection portion. The first electrical connection portion includes an upper portion, a lower portion and a neck portion arranged between the upper portion and the lower portion. An edge of the upper portion is protruded beyond the neck portion, and an edge of the lower portion is protruded beyond the upper portion.