Full-Color LED Pixel Assembly for Uniform DC-Driven Luminance
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Solution Overview
Problem
Current full-color LED displays face challenges in minimizing light blocked by electrodes, achieving uniform luminance, and efficiently connecting ultra-small LED devices to electrodes without electrical short circuits, particularly when using direct current (DC) driving voltage, which limits power selection and results in low luminance and non-uniform color reproducibility.
Innovation Solution
A method of manufacturing full-color LED displays involves forming subpixels with ultra-small LED electrode assemblies using a mounting electrode line with a first and second electrode, applying an asymmetric assembly voltage to self-mount ultra-small LED devices, and performing a thermal process to improve light extraction efficiency and reduce electrical short circuits, allowing for high luminance and uniform color reproducibility with DC driving power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ultra-small LED devices are mounted on electrode lines to reduce pixel size, then high-resolution image quality is achieved, but mounting precision and electrical connection reliability deteriorate due to the extremely small size making pickup and positioning difficult
Solution Approach 1:
A coupling linker is introduced as an intermediary component between the ultra-small LED device and the electrode. The coupling linker has a first coupling portion that connects to the LED and a second coupling portion that connects to the electrode, facilitating reliable electrical connection while accommodating the size constraints of ultra-small LEDs
Solution Approach 2:
The connection system is segmented into three distinct components: the ultra-small LED device, the coupling linker, and the electrode. This segmentation allows each component to be optimized independently, with the coupling linker specifically designed to bridge the gap between the LED's electrode and the display electrode line
2Reliability
If coupling linkers are used to connect ultra-small LED devices to electrodes, then electrical connection is achieved, but mounting difficulty increases particularly for upright mounting between vertically disposed electrode lines
Solution Approach 1:
The coupling linker employs flexible material properties and adjustable geometric parameters to adapt to different mounting configurations. The linker can be deformable or elastically adjustable to accommodate various electrode arrangements including vertical dispositions, making the mounting process more feasible
3Illumination intensity
If AC power is used to drive LED displays with ultra-small devices, then sufficient luminance is achieved, but power selection is limited and DC driving capability is reduced
Solution Approach 1:
The coupling linker incorporates self-aligning or self-adjusting mechanisms that automatically optimize the electrical connection when DC power is applied. The linker may include conductive structures or contact mechanisms that self-adjust to ensure proper current flow direction and maintain reliable connection under DC driving conditions
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 method enhances light extraction efficiency, achieves uniform luminance across pixels, and improves color reproducibility by ensuring a high percentage of ultra-small LED devices are correctly oriented and connected, enabling excellent luminance characteristics even with DC driving power, surpassing the limitations of AC power-driven displays.
Implementation Method 1
applying power, which has an asymmetric assembly voltage of 10 V or more according to Equation 1, to the mounting electrode line such that one end of each of the ultra-small LED devices comes into contact with the first mounting electrode and the other end thereof comes into contact with the second mounting electrode
Implementation Method 2
performing a thermal process to improve light extraction efficiency and reduce electrical short circuits
Data Source
AI summary
A full-color light emitting diode (LED) display having an improved luminance is provided herein. More specifically, provided herein are a full-color LED display, in which an amount of light blocked by electrodes and not extracted is minimized and ultra-small LED devices are connected to ultra-small electrodes without defects such as electrical short circuits and the like, wherein the full-color LED display exhibits a further improved luminance when a direct current (DC) driving voltage is used and each pixel of the full-color LED display exhibits uniform luminance when the DC driving voltage is used, and a method of manufacturing the same.