Light Emitting Element Array Layout for Uniform Boundary Current
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Solution Overview
Problem
Current light emitting element manufacturing processes face defects at the boundary of the shot and unbalanced current distribution due to differences in connection electrode sizes, leading to potential light emitting element misalignment and uneven brightness.
Innovation Solution
A light emitting element array with varying connection electrode sizes and corresponding insulating layer openings, along with a mask having polygonal patterns of different sizes, is used to ensure proportional opening sizes to connection electrodes, addressing size discrepancies and improving current distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection electrodes of uniform size are used for all light emitting elements, then manufacturing process is simplified, but current distribution becomes unbalanced leading to defective boundaries and uneven brightness
Solution Approach 1:
The patent applies local quality by making connection electrodes of different sizes according to their specific positions in the array. Connection electrodes at boundary positions have different dimensions than those at internal positions, optimizing current distribution locally at each position rather than using a uniform design throughout the entire array.
Solution Approach 2:
The patent introduces asymmetry by deliberately designing connection electrodes with different sizes and shapes based on their location. The mask patterns used to form these electrodes are asymmetric, with boundary electrodes having different dimensions than internal electrodes, thereby creating intentional non-uniformity to achieve uniform current distribution across the array.
2Reliability
If mask patterns of different sizes are used to form connection electrodes, then current distribution uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The mask is segmented into different regions with different pattern sizes. The mask includes first mask patterns for boundary light emitting elements and second mask patterns for internal light emitting elements, allowing each region to be optimized independently while maintaining overall manufacturing efficiency through a systematic division of the mask structure.
Solution Approach 2:
The mask is designed as a universal tool that performs multiple functions: it simultaneously forms connection electrodes of different sizes for both boundary and internal light emitting elements in a single manufacturing process. The different mask patterns within the same mask structure enable the formation of various electrode configurations without requiring multiple separate masking steps.
3Ease of manufacture
If all light emitting elements are positioned equally in the array, then manufacturing alignment is simplified, but boundary effects cause defects and reduced performance
Solution Approach 1:
The patent applies local quality by differentiating the treatment of boundary light emitting elements from internal ones. Boundary elements receive specially designed connection electrodes with different dimensions tailored to their specific positional characteristics, thereby addressing boundary effects locally without complicating the overall manufacturing alignment process.
Data Source
AI summary
A light emitting element array includes: a base substrate; a plurality of light emitting elements on the base substrate; an insulating layer on side surfaces and one surface of each of the plurality of the light emitting elements and having an opening on the one surface; and a plurality of connection electrodes, each of the connection electrodes being at the opening in the one surface of the insulating layer of a corresponding one of the plurality of light emitting elements, the connection electrodes of neighboring light emitting elements of the plurality of light emitting elements have a different sizes, and connection electrodes of the plurality of light emitting elements are arranged on the base substrate in a repeating pattern.