LED Panel Structure for Simpler Manufacturing and Longer Life
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Solution Overview
Problem
The manufacturing processes of mini and micro light-emitting diodes (LEDs) are complex, leading to low maturity, low reliability, and high costs, with micro-LEDs facing difficulties in large-size production and short light-emitting life of organic or quantum dot materials, particularly blue light-emitting materials.
Innovation Solution
A display panel design featuring a substrate with a thin-film transistor layer, conductive layers, and light-emitting diodes (LEDs) with specific electrical connections, along with an insulating and light-emitting layer structure, which simplifies the manufacturing process and enhances the service life by using a blue LED with red and green light-emitting layers for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If mini-LEDs or micro-LEDs are used, then the service life of the display panel is extended, but the manufacturing process becomes extremely complicated and costly
Solution Approach 1:
The patent segments the light-emitting function into two independent parts: a blue LED chip that provides the light source and long service life, and organic light-emitting layers (red and green) that provide color. This segmentation allows each component to be manufactured using different, more mature processes, avoiding the complexity of manufacturing entire mini-LED or micro-LED structures while still achieving extended service life through the LED's long-lived blue light emission.
2Duration of action of stationary object
If mini-LEDs or micro-LEDs are used, then the service life is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent merges the advantages of two different technologies: the long service life of LED blue light-emitting chips and the mature, low-cost manufacturing of organic electroluminescent materials. By combining a blue LED chip with organic red and green light-emitting layers, the invention achieves extended service life while utilizing well-established, cost-effective manufacturing processes for the organic layers, thereby reducing overall manufacturing cost compared to pure mini-LED or micro-LED approaches.
3Ease of manufacture
If organic materials or quantum dot materials are used for light-emitting layers, then the manufacturing process is simplified, but the light-emitting life becomes short especially for blue light
Solution Approach 1:
Instead of using organic or quantum dot materials to emit blue light (which have short service lives), the patent inverts the approach by using a blue LED chip to emit blue light and employing organic materials to emit red and green light. This inversion leverages the long service life of blue LEDs while using organic materials only for colors where they have adequate service life, thus resolving the contradiction between manufacturing simplicity and light-emitting durability.
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 simplifies the manufacturing process and extends the service life of the display panel by using a blue LED with red and green light-emitting layers, improving reliability and reducing production costs compared to traditional electroluminescent panels.
Implementation Method 1
at least one light-emitting diode (LED) disposed in the opening
Implementation Method 2
a thin-film transistor layer disposed on the substrate and including a plurality of thin-film transistors
Data Source
AI summary
An embodiment of the application discloses a panel and a manufacturing method thereof. In the panel, a thin-film transistor layer, a first conductive layer, a light-emitting diode (LED), and a second conductive layer are sequentially disposed on a substrate. The LED includes a first end and a second end. The first end is disposed on the first electrode. The second end is disposed on the second electrode. The second conductive layer includes a first conductive portion and a second conductive portion. The first conductive portion is electrically connected to the first end and the first electrode. The second conductive portion is electrically connected to the second end and the second electrode.