Light-Emitting Element Unit Layout for Field-Free Electrode Alignment
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Solution Overview
Problem
Current display device manufacturing processes face inefficiencies in aligning light-emitting elements without applying an electric field, which affects the orientation and light emission efficiency of these elements.
Innovation Solution
A unit of light-emitting elements is developed, where semiconductor layers are stacked in different directions and fixed by a binder, allowing for alignment between electrodes without an electric field, with a 5:5 ratio of opposite stacking directions to ensure half of the elements are oriented in each direction, enhancing light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light-emitting elements are aligned using an electric field, then orientation precision is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies preliminary action by pre-aligning light-emitting elements during the inkjet printing process before device assembly. The elements are oriented correctly during deposition onto the substrate, eliminating the need for subsequent electric field alignment operations. This reduces manufacturing complexity while maintaining alignment precision.
Solution Approach 2:
The patent replaces the electric field alignment system with a mechanical/physical alignment approach during inkjet printing. By controlling the printing process parameters and substrate properties, elements self-align during deposition without requiring complex electric field generation and control systems.
2Productivity
If all light-emitting elements are oriented in the same direction, then light emission efficiency is improved, but manufacturing flexibility decreases
Solution Approach 1:
The patent applies asymmetry by intentionally creating two distinct orientation groups of light-emitting elements rather than uniform alignment. Elements are deposited at different angles or orientations during the inkjet printing process, creating asymmetric orientation patterns that maintain overall light emission efficiency while providing manufacturing flexibility for different device configurations.
Solution Approach 2:
The patent implements dynamics by making the element orientation adjustable and adaptable rather than fixed. The inkjet printing process allows dynamic control of element deposition orientation based on device requirements, enabling the same manufacturing process to produce different orientation patterns as needed.
3Device complexity
If semiconductor layers are stacked in a single direction, then structural simplicity is improved, but light emission uniformity deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the light-emitting element population into multiple orientation groups or segments. Each segment has semiconductor layers stacked in a consistent direction, but different segments have different stacking directions. This segmentation maintains structural simplicity within each group while achieving overall light emission uniformity across the entire device.
Solution Approach 2:
The patent applies local quality by allowing different regions or areas of the device to have different semiconductor layer stacking directions. Each local region maintains consistent stacking for uniform performance in that area, while the overall device achieves enhanced light emission uniformity through the distribution of different orientations across various locations.
Data Source
AI summary
A unit of light-emitting elements includes: a plurality of light-emitting elements; and a binder extending around a periphery of the light-emitting elements and fixing the light-emitting elements. Each of the light-emitting elements includes: first and second semiconductor layers; and an active layer therebetween. A first semiconductor layer, an active layer, and a second semiconductor layer of a first light-emitting element are arranged along a first direction in this order, and a second semiconductor layer, an active layer, and a first semiconductor layer of a second light-emitting element are arranged along the first direction in this order.