Semiconductor LED Display Assembly Using Electric-Field Cell Transfer
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Solution Overview
Problem
Current display technologies, such as LCDs and AMOLEDs, face challenges including slow response time, difficulty in implementing flexibility, short lifespan, and low yield, while semiconductor light-emitting elements struggle to produce large-sized display devices effectively.
Innovation Solution
A display device structure featuring a substrate with partitioned cells, semiconductor light-emitting elements, and a novel manufacturing process that utilizes an electric field formed by electrodes to improve transfer precision and efficiency, allowing for the assembly of semiconductor light-emitting elements without additional masking processes, enabling flexible and large-sized display implementations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If semiconductor light-emitting elements are used to implement flexible displays, then flexibility and response time are improved, but manufacturing complexity and transfer process difficulty increase
Solution Approach 1:
The substrate is divided into multiple cells, each containing a semiconductor light-emitting element. This segmentation allows for simplified manufacturing of individual cells that can be systematically assembled into larger flexible displays, reducing overall manufacturing complexity while maintaining flexibility
Solution Approach 2:
Partition walls are introduced as intermediary structures between adjacent semiconductor light-emitting elements. These partition walls facilitate the transfer and assembly process by providing defined boundaries and alignment references, thereby reducing manufacturing complexity without compromising the flexible nature of the display
2Reliability
If semiconductor light-emitting elements are transferred to wiring substrates, then display performance is improved, but transfer precision and alignment accuracy deteriorate
Solution Approach 1:
Electrode lines are pre-formed on the substrate before transferring the semiconductor light-emitting elements. The partition walls are also prepared in advance to create defined cell structures. This preliminary preparation ensures that when elements are transferred, they align precisely with the pre-established electrode connections, maintaining high transfer precision
Solution Approach 2:
The patent replaces traditional mechanical transfer methods with electric field-based transfer mechanisms. Voltages are applied to the electrode lines to create electric fields that guide and position the semiconductor light-emitting elements during transfer, significantly improving alignment accuracy and transfer precision
3Manufacturing precision
If additional masking processes are used for assembly, then manufacturing precision is improved, but productivity and assembly efficiency deteriorate
Solution Approach 1:
The semiconductor light-emitting elements are designed with built-in alignment features and the partition walls create self-aligning cell structures. During transfer, the elements automatically position themselves relative to the electrode lines and partition walls without requiring external masking processes, thereby maintaining high assembly precision while improving productivity
Solution Approach 2:
The partition walls serve as intermediary alignment references that eliminate the need for masking processes. By providing physical boundaries and alignment cues, the partition walls enable direct placement of semiconductor elements with high precision, improving both assembly efficiency and maintaining manufacturing precision
4Area of stationary object
If large-sized display devices are implemented, then display area is increased, but manufacturing difficulty and transfer process complexity increase
Solution Approach 1:
The large display area is divided into multiple smaller cells arranged in a systematic pattern. Each cell contains a semiconductor light-emitting element and can be manufactured and positioned independently. This segmentation allows large displays to be built from standardized modular units, significantly reducing manufacturing difficulty while achieving large display areas
Solution Approach 2:
The patent creates a universal cell structure with standardized partition walls and electrode line configurations that can be replicated across the entire large display area. This universal design allows the same manufacturing processes to be applied repeatedly to create large displays, reducing overall manufacturing difficulty and complexity
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 assembly efficiency and transfer process precision, enabling the production of flexible and large-sized display devices with improved performance and efficiency, particularly in implementing red, green, and blue semiconductor light-emitting elements.
Implementation Method 1
a substrate; a plurality of cells provided with a partition wall protruding on the substrate, and sequentially arranged along one direction; a semiconductor light-emitting element accommodated in each of the plurality of cells; and a first electrode provided with a plurality of electrode lines arranged on the bottom of each of the cells, and electrically connected to the semiconductor light-emitting element
Implementation Method 2
the electric field may be formed in each of the cells through the second region formed between the electrode lines
Data Source
AI summary
Discussed is a display device, including a substrate including a dielectric layer, a plurality of semiconductor light-emitting devices respectively accommodated on the substrate, and a first electrode provided with a plurality of electrode lines arranged on a bottom of the substrate. Each of the first electrode includes a pair of electrode lines spaced from each other on an upper surface of the dielectric layer among the plurality of electrode lines. Each semiconductor light-emitting device is disposed on the pair of electrode lines, and the pair of electrode lines have the same electrical pole.