Light-Emitting Element Alignment Using Electromagnetic Fields
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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 positioning for display device fabrication, leading to suboptimal performance and manufacturing challenges.
Innovation Solution
A method involving a base substrate with spaced conductive patterns, where light-emitting elements are dispersed in ink and aligned using electromagnetic fields to orient and position them uniformly, utilizing conductive balls and multiple alignment signals to ensure accurate placement and orientation of light-emitting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment methods are used for light-emitting elements, then the alignment process is simpler, but the positioning precision and orientation 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 non-contact positioning and orientation control. This substitution achieves superior alignment precision while reducing mechanical contact and associated errors.
Solution Approach 2:
The patent utilizes changes in electromagnetic field parameters (strength, direction, frequency) to control the alignment process. By adjusting alignment signals applied to conductive patterns, the system can dynamically control the positioning and orientation of light-emitting elements, achieving high precision through parameter optimization rather than mechanical adjustment.
2Manufacturing precision
If multiple alignment signals are applied to control light-emitting elements, then the orientation uniformity improves, but the manufacturing time increases
Solution Approach 1:
The patent employs periodic application of multiple alignment signals in a coordinated sequence. Different conductive patterns are activated in specific sequences, with each signal serving a particular function (positioning, orientation, fine-tuning). This periodic, multi-stage approach achieves uniform orientation while managing process time through optimized signal timing and duration.
Solution Approach 2:
The patent performs preliminary positioning using conductive patterns before final orientation adjustment. Initial alignment signals establish rough positions, followed by refined orientation signals that precisely control element orientation. This preliminary action approach divides the alignment process into stages, achieving high precision without requiring all signals to operate simultaneously, thus improving efficiency.
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 alignment and orientation of light-emitting elements, improving the efficiency of display device fabrication by ensuring uniform spacing and orientation, which enhances the performance and reliability of the final display devices.
Implementation Method 1
applying a first alignment signal to the plurality of conductive patterns to generate a first electromagnetic field on the plurality of conductive patterns, and positioning at least a portion of the plurality of light-emitting elements on the plurality of conductive patterns
Implementation Method 2
the plurality of light-emitting elements each independently may include 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 may comprise seating the conductive balls of the at least a portion of the plurality of light-emitting elements on the conductive patterns
Implementation Method 3
applying a second alignment signal to the first alignment electrode and the second alignment electrode to generate a second electromagnetic field on the base substrate, and to change the positions and/or orientations of the plurality of light-emitting elements
Data Source
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.