Light-Emitting Element Insulation Structure for Surface Defect Control
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Solution Overview
Problem
Existing light emitting elements face issues with reliability and efficiency due to surface defects and potential short circuits, particularly in densely packed displays.
Innovation Solution
A multi-layer insulating film comprising a first layer, a second layer, and a third layer is applied to the outer circumferential surface of a light emitting stack pattern, where the first and third layers share the same material, and the second layer has a different material, to enhance protection and prevent surface defects and short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer insulating film is used to surround the light emitting stack pattern, then the device structure is simple and manufacturing is easier, but surface defects occur and short circuits may happen due to insufficient protection
Solution Approach 1:
The insulating film is divided into multiple layers (first insulating layer, second insulating layer, and third insulating layer) with different materials and functions. Each layer provides specific protection: the first layer prevents surface defects, the second layer provides additional insulation, and the third layer offers final protection, collectively solving the reliability issue without excessive complexity.
Solution Approach 2:
The patent uses composite material structure for the insulating film, combining different insulating materials in multiple layers. This composite approach enhances the overall protective performance and reliability by leveraging the strengths of each material, while the systematic arrangement keeps the manufacturing process manageable.
2Reliability
If the insulating film layers are made thick to improve protection, then reliability increases, but manufacturing precision requirements increase and production becomes more difficult
Solution Approach 1:
Instead of using a single thick insulating layer that would be difficult to manufacture with precise thickness control, the patent segments the insulation into multiple thinner layers. Each layer can be manufactured with more precise and manageable thickness, while collectively providing the required total protection and reliability.
3Productivity
If densely packed displays are manufactured, then productivity increases, but the risk of short circuits between adjacent light emitting elements increases
Solution Approach 1:
The multi-layer insulating film structure with different materials provides enhanced electrical insulation and physical separation between densely packed light emitting elements. This composite insulation system maintains reliable short circuit prevention even when elements are closely spaced, enabling higher productivity without sacrificing reliability.
Data Source
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AI summary
A light emitting element may include: a light emitting stack pattern including a first semiconductor layer, an active layer, and a second semiconductor layer; and an insulating film surrounding an outer circumferential surface of the light emitting stack pattern. The insulating film may include: a first layer; a second layer surrounding the first layer; and a third layer surrounding the second layer. The first layer and the third layer may include the same material.