LED Electrode Taper Structure for Misalignment-Tolerant Display Transfer
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Solution Overview
Problem
The production of display devices using LED elements is hindered by high production costs due to expensive semiconductor substrates and difficulties in accurately transferring LED elements from semiconductor substrates to display devices, leading to defects and increased defect rates during the transfer process.
Innovation Solution
A light-emitting device with an inverted tapered structure between its n-type and p-type electrodes, which minimizes defects during electrical connection and improves stability, allowing for precise alignment and reduced defect rates even if the LED is misaligned during transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If LED elements are transferred from semiconductor substrates to display devices, then the display device can be manufactured with LED light-emitting elements, but the transfer process causes misalignment defects and increases production costs
Solution Approach 1:
The patent applies preliminary action by pre-forming the inverted tapered structure on the semiconductor substrate before transferring the LED element. This pre-prepared structure ensures that even if misalignment occurs during transfer, the electrodes will still connect properly, thereby resolving the contradiction between ease of manufacture and manufacturing precision
Solution Approach 2:
The inverted tapered structure acts as a cushioning mechanism against misalignment defects. By designing the electrode structure with gradual tapering, the patent creates a tolerance zone that absorbs positioning errors during the transfer process, preventing defective connections and reducing defect rates
2Device complexity
If conventional flat electrode structures are used, then the manufacturing process is simple, but misalignment during transfer causes defective connections between electrodes
Solution Approach 1:
The patent employs asymmetry by designing the electrode structure with an inverted tapered shape instead of a conventional flat or symmetric structure. This asymmetric geometry provides directional guidance for alignment and creates a self-correcting feature that maintains reliable electrical connection even when misalignment occurs, thereby improving reliability without significantly increasing device complexity
Solution Approach 2:
The patent changes the geometric parameters of the electrode structure by introducing an inverted taper angle. This parameter modification transforms the electrode from a flat surface to a three-dimensional tapered structure, which provides tolerance to misalignment and ensures reliable connections, resolving the contradiction between device complexity and reliability
3Reliability
If precise alignment is required during LED transfer, then connection reliability improves, but the transfer process becomes more difficult and defect rates increase
Solution Approach 1:
The inverted tapered structure enables self-alignment functionality, where the geometry of the structure itself guides the connection process. The taper angle naturally directs the electrode toward proper alignment, allowing the structure to serve its own alignment function without requiring external alignment mechanisms, thereby improving connection reliability while maintaining ease of manufacture
Data Source
AI summary
A light-emitting device and a display including the same can improve the process stability during the process of disposing the light-emitting device. A light-emitting device includes the n-type semiconductor layer and the p-type semiconductor layer, and a structure is disposed so as to minimize electrical short between electrodes even if the light-emitting device is misaligned. The structure may have at least one side surface in an inverted taper shape and may be disposed between electrodes to minimize a short-circuit therebetween during the process of connecting the electrodes.