LED Display Electrode Structure Without Precise Alignment
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Solution Overview
Problem
The existing display device manufacturing processes face challenges in aligning light emitting diodes (LEDs) properly with electrodes, leading to potential defects where LEDs may not emit light, which complicates the manufacturing process and reduces efficiency.
Innovation Solution
A display device structure and manufacturing method that includes a base layer, pixel circuit, pixel electrode, a middle layer with a polymer resin and conductive particles, and a common electrode, where the conductive particles are condensed between the pixel electrode and LEDs during the heating process, eliminating the need for precise LED alignment and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light emitting diodes are separately formed and connected to electrodes, then the display device can be manufactured with modular components, but the manufacturing process becomes complex due to the requirement of precise alignment
Solution Approach 1:
The patent merges the light emitting diode and the electrode into a single integrated structure. The electrode is formed within the light emitting diode device itself, eliminating the need for separate alignment processes. This integration resolves the contradiction by maintaining modular manufacturing benefits while removing the complex alignment requirement between separate components.
Solution Approach 2:
The electrode is formed in advance within the light emitting diode structure during the same manufacturing process. This preliminary formation of the electrode eliminates the subsequent alignment step that would be required if electrodes and light emitting diodes were manufactured separately and then assembled.
2Adaptability or versatility
If light emitting diodes are separately formed and connected to electrodes, then component flexibility is improved, but manufacturing time increases due to alignment requirements
Solution Approach 1:
By combining the electrode formation with the light emitting diode manufacturing process, the patent eliminates the time-consuming alignment step while preserving component flexibility. The integrated approach allows both components to be manufactured together in a single process flow.
Solution Approach 2:
The electrode is preliminarily formed within the light emitting diode structure before final assembly. This advance preparation eliminates the need for time-consuming alignment operations during subsequent manufacturing stages, thereby reducing overall manufacturing time while maintaining design flexibility.
3Reliability
If precise LED alignment on electrode is required, then electrical connection reliability is improved, but the manufacturing process becomes more difficult and error-prone
Solution Approach 1:
The patent merges the electrode and light emitting diode into an integrated structure where the electrode is formed within the diode device. This integration ensures reliable electrical connection by design, eliminating the alignment errors that occur when separate components are assembled. The manufacturing process becomes simpler as the alignment step is removed entirely.
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 approach ensures that even if one LED does not emit light, others on the same pixel electrode can, reducing the probability of defective pixels and simplifying the manufacturing process by eliminating the need for precise LED alignment.
Implementation Method 1
heating the middle layer to condense the conductive particles on the pixel electrode
Data Source
AI summary
Provided is a display device including a base layer, a pixel circuit disposed on the base layer, a pixel electrode electrically connected to the pixel circuit, a middle layer disposed on the pixel electrode and including a polymer resin layer and a conductive layer, a plurality of light emitting diodes disposed on the conductive layer and electrically connected to the pixel electrode, and a common electrode configured to cover the plurality of light emitting diodes and electrically connected to the plurality of light emitting diodes. Each of the plurality of light emitting diodes includes a first electrode, a light generating layer, and a second electrode sequentially stacked in a thickness direction of the base layer.