Light-Emitting Element Alignment Using Electromagnetic Conductive Patterns
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Solution Overview
Problem
Current methods for aligning light-emitting elements on substrates lack precision and efficiency, particularly in achieving uniform orientation and spacing for the fabrication of high-quality display devices like OLED panels, where precise alignment is crucial for optimal performance and image quality.
Innovation Solution
A method involving the use of conductive patterns on a substrate to attract and orient light-emitting elements using electromagnetic fields, ensuring uniform spacing and alignment by applying specific electromagnetic signals to guide the positioning and orientation of the elements, which includes seating conductive balls on the patterns and rotating them to align with the desired direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment methods are used for light-emitting elements, then the fabrication process is simpler, but the alignment precision and uniformity deteriorate
Solution Approach 1:
The patent replaces conventional mechanical alignment methods with electromagnetic field-based alignment. Conductive patterns generate electromagnetic fields that interact with conductive balls on light-emitting elements, enabling precise positioning and orientation without mechanical contact or complex mechanical alignment mechanisms.
Solution Approach 2:
The patent utilizes changes in electromagnetic field parameters (strength, direction, frequency) to control the positioning and orientation of light-emitting elements. By adjusting the electromagnetic field parameters, precise alignment is achieved while maintaining process flexibility and control.
2Manufacturing precision
If conventional alignment methods are used, then the process is faster, but the uniformity of element orientation deteriorates
Solution Approach 1:
The electromagnetic field-based alignment system performs multiple functions simultaneously: positioning light-emitting elements at specific locations, orienting them in uniform directions, and controlling their spacing. This multi-functional approach achieves high orientation uniformity without sacrificing productivity, as all alignment operations are conducted through the same electromagnetic field mechanism.
Solution Approach 2:
By replacing mechanical alignment with electromagnetic field control, the system achieves uniform orientation across all light-emitting elements while maintaining high throughput. The electromagnetic fields can simultaneously act on multiple elements, ensuring consistent orientation without the slow, sequential nature of mechanical alignment.
3Manufacturing precision
If electromagnetic fields are used for alignment, then alignment precision improves, but energy consumption increases
Solution Approach 1:
The electromagnetic fields are applied in a controlled, partial manner rather than continuously at full strength. The field strength and duration are optimized to achieve the necessary positioning accuracy with minimal energy input, avoiding excessive energy consumption while maintaining high positioning precision.
Solution Approach 2:
The patent optimizes electromagnetic field parameters (strength, frequency, duration) to achieve the minimum energy requirement for precise alignment. By carefully controlling these parameters, the system achieves high positioning accuracy while minimizing energy consumption compared to continuous or high-strength field applications.
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
This approach enables precise and uniform alignment of light-emitting elements, improving the efficiency of display device fabrication by ensuring accurate placement and orientation, leading to enhanced performance and image quality in display devices.
Implementation Method 1
providing a base substrate on which a plurality of conductive patterns are spaced apart from one another; applying a first alignment signal to the plurality of conductive patterns to form a first electromagnetic field on the plurality of conductive patterns; the plurality of light-emitting elements each independently includes conductive balls to which an attractive force is to be applied by the first electromagnetic field
Implementation Method 2
the plurality of light-emitting elements each independently includes conductive balls to which an attractive force is to be applied by the first electromagnetic field, and the positioning of the plurality of light-emitting elements includes seating the conductive balls on the conductive patterns
Implementation Method 3
the orienting of the plurality of light-emitting elements includes applying a third alignment signal to the plurality of conductive patterns to generate a third electromagnetic field stronger than the first electromagnetic field; one end of each of the plurality of light-emitting elements that are positioned on the plurality of conductive patterns may be oriented in the first direction
Data Source
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AI summary
A method of aligning light-emitting elements, a method of fabricating a display device, and a display device are provided. The method of aligning light-emitting elements comprises providing a base substrate and a plurality of conductive patterns on the base substrate and spaced apart from one another, spraying ink in which a plurality of light-emitting elements are dispersed on the base substrate, positioning the plurality of light-emitting elements on the conductive pattern and orienting one end of each of the plurality of light-emitting elements in a first direction.