LED Package Structure for Self-Alignment in High-Resolution Displays
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Solution Overview
Problem
The existing self-assembly methods for light emitting diodes in display devices are inefficient due to long process times, electrical connection issues, and color reproducibility problems caused by the different sizes and shapes of red, green, and blue light emitting devices, which hinder the assembly of high-resolution displays.
Innovation Solution
A light emitting device package with a circular shape and a substrate having corresponding grooves allows for easy alignment and rotation, combined with a multi-layer structure for electrical connection, enabling efficient assembly and reducing assembly time by allowing 360-degree rotation and preventing electrical shorts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate assembly processes are used for each color light emitting device (red, green, blue), then assembly precision can be maintained for each device, but the total assembly time becomes very long
Solution Approach 1:
The patent combines multiple separate assembly processes for red, green, and blue light emitting devices into a single simultaneous assembly operation. All three color devices are dropped and assembled together in one process step, eliminating the sequential nature of previous methods and dramatically reducing total assembly time while maintaining assembly precision through unified process control
2Productivity
If different shapes and sizes are used for red, green, and blue light emitting devices to enable simultaneous assembly, then assembly efficiency improves, but color gamut decreases due to different light amounts
Solution Approach 1:
The patent makes all light emitting devices (regardless of color) share the same shape and size, enabling them to be assembled simultaneously in the same process. This universal design allows red, green, and blue devices to be dropped and assembled together without the need for different geometries, thereby maintaining color gamut while improving assembly efficiency
3Measurement precision
If light emitting devices are aligned in reduced size pixels for high resolution, then display resolution improves, but the difficulty of alignment and assembly increases significantly
Solution Approach 1:
The patent employs a self-assembly mechanism where light emitting devices automatically align and position themselves into the pixel array during the dropping process. The devices utilize their own properties and the assembly environment to achieve precise positioning in high-resolution displays without requiring complex external alignment systems or manual positioning procedures
4Loss of time
If simultaneous assembly of multiple color light emitting devices is implemented, then assembly time is reduced, but electrical connection reliability may be compromised
Solution Approach 1:
The patent incorporates preliminary electrical connection structures and designs that are prepared in advance to handle simultaneous assembly of multiple color devices. The electrical connection architecture is pre-configured to ensure reliable connections are established during the concurrent assembly process, preventing connection failures that might otherwise occur with multiple devices being assembled at the same time
Data Source
AI summary
A light emitting device package include a first layer; a plurality of light emitting devices on the first layer; a plurality of electrode pads surrounding the plurality of light emitting devices; a second layer on the plurality of light emitting devices; a plurality of connection electrodes disposed on the second layer to connect between the plurality of light emitting devices and the plurality of electrode pads, and a third layer on the plurality of connection electrodes.