Light Emitting Element Alignment Structure for Flow-Assisted Transfer Yield
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Solution Overview
Problem
Existing display device manufacturing processes face challenges in efficiently aligning light emitting elements, particularly in moving dummy light emitting elements from non-alignment areas to alignment areas, which affects transfer yield.
Innovation Solution
The proposed alignment structure utilizes a flow supplied to a fluid layer to move a dummy light emitting element from a non-alignment area to an alignment area, where it is aligned with electrodes using an electric field, thereby increasing transfer yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If light emitting elements are provided to the base substrate through a fluid layer, then the transfer yield is improved, but dummy light emitting elements in non-alignment areas reduce the overall alignment efficiency
Solution Approach 1:
The patent extracts and removes dummy light emitting elements from non-alignment areas through a multi-step process: first identifying elements in non-alignment areas, then applying flow to move them to alignment areas, and finally removing excess elements. This extraction process resolves the contradiction by eliminating the harmful dummy elements that reduce alignment accuracy while preserving the high transfer yield benefit.
Solution Approach 2:
The patent introduces dynamic flow control to move light emitting elements from non-alignment areas to alignment areas. By applying controlled flow through flow supply lines, the system dynamically adjusts element positions during the transfer process, transforming static misaligned elements into dynamically repositioned aligned elements, thereby resolving the alignment accuracy issue.
2Manufacturing precision
If a flow is applied to move dummy light emitting elements from non-alignment areas, then the alignment probability is improved, but the device complexity increases
Solution Approach 1:
The patent segments the flow supply system into multiple independent flow supply lines, each controlling specific regions of the base substrate. This segmentation allows precise local control of element movement without requiring a complex global control system, resolving the contradiction between alignment accuracy and device complexity by distributing the control function across simpler modular units.
Solution Approach 2:
The patent introduces a flow medium as an intermediary between the flow supply apparatus and the light emitting elements. This intermediary translates electrical control signals into physical movement of elements, simplifying the direct control mechanism and reducing the complexity of the overall system while maintaining precise alignment capability.
3Ease of operation
If multiple flow injectors are provided at intervals in the non-alignment area, then the element movement control is improved, but the manufacturing cost increases
Solution Approach 1:
The patent designs flow injectors with multi-functionality, where each injector can serve multiple purposes: moving elements during transfer, repositioning dummy elements, and controlling flow patterns in different regions. This universal design reduces the total number of injectors needed compared to having dedicated components for each function, thereby reducing manufacturing cost while maintaining ease of operation.
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 enhances the transfer yield of light emitting elements by increasing the probability of alignment with electrodes, improving the manufacturing efficiency of display devices.
Implementation Method 1
moving a second light emitting element provided to the non-alignment area of the base substrate to the alignment area by applying a flow to the fluid layer
Implementation Method 2
aligning a first light emitting element provided to the alignment area of the base substrate to at least one electrode using an electric field
Implementation Method 3
lowering at least one of the plurality of light emitting elements in a vertical direction by gravity in a gravitational influence zone of the fluid layer
Data Source
AI summary
A method of manufacturing a display device including: providing a plurality of light emitting elements to a base substrate through a fluid layer, the base substrate including an alignment area and a non-alignment area; aligning a first light emitting element provided to the alignment area of the base substrate to at least one electrode using an electric field; and moving a second light emitting element provided to the non-alignment area of the base substrate to the alignment area by applying a flow to the fluid layer.