LED Structure With Selective Insulation for Electrode Contact
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Solution Overview
Problem
Existing LED manufacturing processes can damage the LED due to the formation of an insulating film on its outer periphery, leading to failure, and there is a need to improve the contact area with electrodes.
Innovation Solution
A method of manufacturing a light emitting element with a first conductive semiconductor layer partially exposed by an insulating film, forming an emissive stack pattern, and including an electrode layer to enhance contact area and protect against external damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating film is formed on the outer periphery of the LED, then the LED structure is protected and enclosed, but the LED may be damaged during the process, resulting in failure
Solution Approach 1:
The patent applies preliminary action by forming a protective coating layer on the LED surface before forming the insulating film. This pre-protective measure prevents damage during the insulating film formation process, thereby improving manufacturing success rate while maintaining the protective function of the insulating film
2Reliability
If the insulating film covers the entire outer periphery of the LED, then the LED is fully protected, but the contact area with electrodes is reduced
Solution Approach 1:
The patent applies local quality by selectively positioning the insulating film to cover only specific regions of the LED outer periphery, while leaving other regions exposed for electrode contact. This creates different functional zones: protected areas with insulating film and contact areas without film, thereby maintaining both protection and electrical connectivity
3Duration of action of stationary object
If the LED is manufactured with complete insulation, then durability is improved, but manufacturing complexity increases due to potential damage risks
Solution Approach 1:
The patent reduces manufacturing process complexity by implementing a preliminary protective coating step that prevents damage during insulating film formation. This preliminary protection simplifies the overall process by reducing failure rates and rework requirements, thereby improving LED lifetime without significantly increasing manufacturing complexity
Data Source
AI summary
A light emitting element includes a first semiconductor layer; an active layer on a surface of the first semiconductor layer; a second semiconductor layer on the active layer; an insulating film to enclose an outer periphery of each of the first semiconductor layer, the active layer, and the second semiconductor layer; and an electrode layer on the second semiconductor layer. The first semiconductor layer includes a first area that is covered by the insulating film, and a second area that is not covered by the insulating film. A perimeter of the outer periphery of the first semiconductor layer in the first area and a perimeter of the outer periphery of the first semiconductor layer in the second area are different from each other.