LED Electrode Contact Structure to Prevent Alignment Short Circuits
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Solution Overview
Problem
The challenge in manufacturing light emitting devices is the occurrence of short circuits between electrodes due to unintended particles during the alignment of nano-sized light emitting diodes, which affects the number of diodes that can be effectively connected between the electrodes.
Innovation Solution
A light emitting device design that includes a substrate with spaced apart electrodes, nano-sized light emitting diodes aligned by an electric field, and a method of forming contacts and an insulation pattern to prevent particle-induced short circuits, ensuring all diodes are connected to the electrodes, even if they are not perfectly aligned during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If nano-sized light emitting diodes are sprayed and aligned on electrodes by forming an electric field, then the number of light emitting diodes between electrodes is increased, but short circuits may occur due to unintended particles during alignment
Solution Approach 1:
The patent introduces an intermediary substance (conductive adhesive or conductive paste) between the light emitting diodes and electrodes to ensure reliable electrical connection. This intermediary material fills gaps and prevents short circuits caused by particle contamination during the spray alignment process, while still enabling effective electrical connection between the nano-sized diodes and electrodes.
Solution Approach 2:
The patent applies preliminary action by pre-coating the electrodes with conductive adhesive or paste before spraying the light emitting diodes. This preliminary preparation ensures that when diodes are aligned by electric field, they make reliable electrical contact without causing short circuits, even in the presence of particles during the alignment process.
2Productivity
If light emitting diodes are aligned by electric field between spaced electrodes, then all diodes can be connected to electrodes, but manufacturing precision is affected by particle contamination
Solution Approach 1:
The conductive adhesive acts as a mediator that compensates for alignment imprecision. It fills the gaps between misaligned diodes and electrodes, ensuring electrical connection is maintained even when particle contamination causes positioning errors during the spray alignment process.
Solution Approach 2:
The patent changes the physical state and properties of the contact interface by using conductive paste with adjustable viscosity and conductivity parameters. This allows the material to flow and adapt to slight misalignments caused by particles, while maintaining effective electrical connection between diodes and electrodes.
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 solution increases the number of connected light emitting diodes between electrodes while preventing short circuits, enhancing light emission efficiency and ensuring all diodes emit light, even if they are initially spaced from the electrodes during the manufacturing process.
Implementation Method 1
aligning the light emitting diodes between the first electrode and the second electrode by forming an electric field between the first electrode and the second electrode
Data Source
AI summary
A light emitting device includes: a substrate; a first electrode and a second electrode on the substrate and spaced apart from each other; a light emitting diode between the first electrode and the second electrode and connected to the first and second electrodes; a first contact on the first electrode; and a second contact on the second electrode. The first contact contacts the first electrode and a first portion of the light emitting diode, and the second contact contacts the second electrode and a second portion of the light emitting diode.