Self-Assembled LED Electrode Layout for Misalignment Tolerance

The light-emitting elements are designed with self-aligning features including convex portions on the elements that fit into concave portions of the electrodes. This self-service mechanism allows the elements to automatically align with their target positions during transfer, eliminating the need for complex external alignment systems and reducing manufacturing process complexity while maintaining high alignment precision.

The patent introduces intermediary structures (convex portions on light-emitting elements and corresponding concave portions on electrodes) that act as mediators between the light-emitting elements and the electrodes. These intermediary features facilitate precise alignment and stable electrical connection, simplifying the overall manufacturing process by providing a built-in alignment mechanism rather than requiring complex external positioning systems.

The light-emitting elements incorporate self-aligning convex portions that automatically engage with concave portions of the electrodes during the transfer process. This self-service feature ensures reliable alignment and stable electrical connection without requiring complex external alignment systems, thereby maintaining ease of manufacture while significantly improving operational reliability by preventing misalignment issues.

The patent designs the light-emitting elements with pre-formed convex portions and the electrodes with corresponding concave portions that act as beforehand cushioning features. These pre-designed alignment features ensure that even if minor misalignments occur during transfer, the convex-concave engagement provides a tolerance buffer that maintains reliable electrical connection and normal operation, thereby improving reliability without complicating the manufacturing process.

The patent employs asymmetric electrode configurations where the electrodes have concave portions specifically shaped to receive the convex portions of the light-emitting elements. This asymmetric design provides adaptability by creating a directional fit that guides the elements into correct alignment during transfer, while the concave features provide tolerance for minor misalignments. The asymmetric structure maintains ease of manufacture as it can be fabricated using standard photolithography and etching processes.

The electrodes are designed with local quality variations, featuring concave portions at specific locations where light-emitting elements will be positioned. These localized concave features provide adaptability by creating targeted alignment zones that accommodate element placement, while the rest of the electrode structure maintains simple fabrication. This local modification approach enables misalignment tolerance without requiring complete redesign of the entire electrode system.