Light-Emitting Element Structure for Active Layer Protection
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Solution Overview
Problem
Existing methods for manufacturing display devices face challenges in securing a sufficient width of the active layer relative to the light emitting element while minimizing damage to the active layer during processing.
Innovation Solution
The method involves forming a light emitting element with a structure comprising a first element rod with a first inclination angle, a second element rod with a second inclination angle smaller than the first, and a third element rod with a third inclination angle, all surrounded by a protective layer and connected by contact electrodes. This structure ensures the active layer's width is maintained while reducing damage during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the active layer width is increased relative to the light emitting element, then the manufacturing precision and reliability improve, but the device complexity and processing difficulty increase
Solution Approach 1:
The element rod is divided into three distinct segments (first, second, and third element rods) with different inclination angles. This segmentation allows each part to serve a specific function: the first rod provides structural support, the second rod (with smaller inclination angle) protects the active layer width, and the third rod enables proper electrical connection. By dividing the structure into functional segments, the patent achieves precise active layer width control without overwhelming complexity.
Solution Approach 2:
Different portions of the element rod structure are given different inclination angles tailored to their specific functions. The first element rod has a larger inclination angle for structural stability, the second element rod has a smaller inclination angle specifically to maintain active layer width, and the third element rod has its own inclination angle for connection purposes. This local differentiation of geometric properties enables precise control of the active layer width while keeping each segment's design optimized and manageable.
2Object-affected harmful factors
If the inclination angle of the element rod is reduced to protect the active layer, then the active layer damage decreases, but the structural stability and electrical connection reliability may worsen
Solution Approach 1:
The structure is segmented into three element rods with different inclination angles, allowing the second rod to have a smaller angle for protection while the third rod maintains a suitable angle for reliable electrical connection. This segmentation resolves the contradiction by distributing different functional requirements to different segments rather than requiring a single compromise design.
Solution Approach 2:
The inclination angle is locally optimized for each element rod segment based on its specific function. The second element rod has a smaller inclination angle specifically where the active layer is most vulnerable, while the third element rod has an inclination angle optimized for electrical connection reliability. This local quality adjustment allows simultaneous achievement of damage reduction and connection reliability.
3Object-affected harmful factors
If a protective layer is added around the element rod, then the active layer is protected from damage, but the manufacturing process complexity increases
Solution Approach 1:
The protective layer serves multiple functions simultaneously: it physically protects the active layer during processing, provides electrical insulation between different conductive elements, and maintains the structural integrity of the element rod assembly. By making the protective layer multi-functional, the patent reduces the need for additional separate components, thereby limiting the increase in manufacturing complexity while achieving comprehensive protection.
Solution Approach 2:
The protective layer acts as an intermediary element between the element rod structure and the external environment, as well as between different functional components. This intermediary layer simplifies the overall manufacturing process by providing a single protective and insulating barrier rather than requiring multiple separate protective measures, thus limiting the increase in process complexity.
Data Source
AI summary
A light emitting element includes a first element rod including a first semiconductor layer and an active layer and having a first inclination angle on a side surface; a second element rod on the first element rod and having a second inclination angle on a side surface; a third element rod on the second element rod and having a third inclination angle on a side surface, the second inclination angle being smaller than the first inclination angle and the third inclination angle; a protective layer around one side and an other side of the first element rod, a side of the second element rod, and a side of the third element rod; and a contact electrode around the protective layer and electrically connected to the first semiconductor layer.