Magnetic-Assisted Micro-LED Alignment for Higher Display Luminance
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Solution Overview
Problem
In display devices, misalignment of light emitting elements due to limited dielectrophoretic force alignment results in wasted costs and reduced luminance, as misaligned elements are not electrically connected and hinder the light emission of aligned ones.
Innovation Solution
A display device with a substrate, first and second electrodes, and magnetic layers where light emitting elements are aligned primarily by dielectrophoretic force and secondarily by magnetic force, enhancing alignment and luminance, and a blocking layer to prevent magnetic layer attachment and facilitate collection of misaligned elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dielectrophoretic force alignment is used to align light emitting elements between electrodes, then alignment is achieved within a predetermined angle range, but light emitting elements positioned beyond this angle range are not aligned and cannot be electrically connected
Solution Approach 1:
The invention introduces a magnetic layer segmented into multiple regions with different magnetic pole arrangements. First magnetic layers have N-poles facing the first electrode to align N-type light emitting elements, while second magnetic layers have N-poles facing the second electrode to align P-type light emitting elements. This segmentation allows different regions to handle different polarity orientations independently.
Solution Approach 2:
The magnetic layer acts as an intermediary between the electrodes and light emitting elements. By generating magnetic fields in addition to the electric fields from electrodes, the magnetic layers mediate the alignment process for light emitting elements that cannot be aligned by electric fields alone, particularly those with orientations beyond the predetermined angle range.
2Ease of manufacture
If light emitting elements are not aligned with pixels, then manufacturing cost increases due to wasted elements, but implementing more comprehensive alignment increases device complexity
Solution Approach 1:
The magnetic layers serve multiple functions: they generate magnetic fields for aligning light emitting elements, provide structural support between electrodes, and enable both N-type and P-type element alignment through different regional configurations. This multi-functionality reduces the need for separate alignment mechanisms for different element types.
Solution Approach 2:
The invention changes the physical parameter approach by introducing magnetic field parameters in addition to electric field parameters. By controlling magnetic pole orientations and strengths in different regions, the system achieves comprehensive alignment coverage without requiring complex mechanical or chemical alignment processes.
3Productivity
If misaligned light emitting elements are not collected, then manufacturing cost increases, but implementing collection mechanisms increases processing time
Solution Approach 1:
The magnetic layers enable misaligned light emitting elements to be self-collected. By configuring magnetic poles such that misaligned elements experience magnetic attraction toward edges or specific regions, the system automatically gathers misaligned elements without requiring external collection mechanisms or additional processing steps.
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
Improves the alignment of light emitting elements, increases luminance by ensuring more elements are electrically connected, and reduces manufacturing costs through efficient collection of misaligned elements.
Implementation Method 1
an alignment technology using dielectrophoretic force formed between electrodes. That is, an electric field is formed between the two electrodes by voltage applied to the two electrodes. When the light emitting element is positioned around the two electrodes, holes and electrons of the light emitting element move according to the electric field formed between the two electrodes to align the light emitting element between the two electrodes.
Implementation Method 2
light emitting elements that is not aligned in the primary alignment by using the magnetic force of the magnetic layer are secondary aligned
Data Source
AI summary
A display device comprises a substrate comprises a substrate comprising a plurality of sub pixels, a first electrode in the plurality of sub pixels, a second electrode in the plurality of sub pixels, and adjacent to the first electrode, a first magnetic layer between the first electrode and the second electrode, and a plurality of light emitting elements between the first electrode and the second electrode. The light emitting element comprises at least one second magnetic layer in contact with the magnetic layer.