LED Conductive Layer Cushion Structure for Detachment Damage Prevention
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Solution Overview
Problem
LED chips are prone to damage and short circuits during the detachment process from blue tape due to the mechanical strength of the flip chip LED being insufficient, leading to cracks and reliability issues.
Innovation Solution
Incorporating a cushion part between the conductive layers of the LED structure, which is electrically isolated and designed to absorb the detaching force, preventing cracks and short circuits during the detachment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the ejector pin pushes the flip chip LED to detach it from the blue tape, then the LED can be removed from the tape, but the mechanical strength is insufficient causing cracks and damage to the LED
Solution Approach 1:
A cushion part made of insulating material is introduced as an intermediary element between the conductive layers of the LED chip. This cushion part absorbs the mechanical stress during the detachment process, preventing direct transmission of force to the fragile LED structure and avoiding cracks while maintaining electrical isolation between conductive layers.
2Productivity
If the ejector pin applies force to detach the LED from the blue tape, then the LED can be removed, but short circuits occur due to crack damage
Solution Approach 1:
The cushion part is pre-positioned between the conductive layers before the detachment process occurs. This beforehand cushioning ensures that when the ejector pin applies force during detachment, the stress is absorbed by the cushion part rather than propagating through the LED structure, preventing crack formation and subsequent short circuits.
Solution Approach 2:
The insulating cushion part serves as a mediator that decouples the mechanical detachment force from the electrical conductive paths. It allows the detachment operation to proceed while maintaining electrical integrity by preventing stress-induced cracks that would otherwise create short circuits between conductive layers.
3Device complexity
If no cushion part is used during detachment, then the structure remains simple, but the LED chip suffers from cracks and damage
Solution Approach 1:
The cushion part is designed as a simple, inexpensive insulating element that can be easily integrated into the LED chip structure. Although it adds a component, its simple construction from standard insulating materials keeps the overall complexity increase minimal while providing substantial protection against detachment damage.
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 cushion part effectively prevents cracks and short circuits, ensuring the reliability and integrity of the LED chips during the detachment process.
Implementation Method 1
a cushion part disposed on and directly contacts the first conductive layer... the cushion part is surrounded by and electrically isolated from the second conductive layer
Implementation Method 2
the cushion part is surrounded by and electrically isolated from the second conductive layer
Data Source
AI summary
A light-emitting element includes a semiconductor light-emitting stack including a first semiconductor layer, a second semiconductor layer formed on the first semiconductor layer, and an active layer formed therebetween; a first conductive layer disposed on the second semiconductor layer and electrically connecting the second semiconductor layer; a second conductive layer disposed on the second semiconductor layer and electrically connecting the first semiconductor layer; and a cushion part disposed on and directly contacts the first conductive layer, wherein in a top view, the cushion part is surrounded by and electrically isolated from the second conductive layer.