Micro LED Alignment via Insulating Stopper Thickness
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Solution Overview
Problem
Micro light emitting elements are difficult to align between electrodes due to their nano-scale size, which poses challenges in manufacturing and reduces the efficiency of display devices.
Innovation Solution
A display device design featuring a stopper area with varying thickness and inclined surfaces between two electrodes, allowing for precise alignment of micro light emitting elements using electric fields and photoresist patterns, enabling easy placement and improved alignment reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If micro light emitting elements are used to reduce space and improve display performance, then device performance is improved, but alignment precision deteriorates due to nano-scale size
Solution Approach 1:
The patent introduces a stopper layer as an intermediary component between the electrodes and micro light emitting elements. This stopper layer with controlled thickness and inclined surfaces serves as a physical mediator that facilitates the alignment and placement of nano-scale light emitting elements, resolving the alignment precision issue while maintaining the use of small-sized elements for high performance
Solution Approach 2:
The stopper layer is formed in advance before placing the micro light emitting elements. The inclined surfaces and specific thickness distribution are prepared beforehand to guide and facilitate the alignment process, making it easier to position the nano-scale elements accurately without requiring complex real-time alignment mechanisms
2Ease of manufacture
If conventional light emitting elements are erected and connected to electrodes, then ease of manufacture is improved, but device complexity increases due to three-dimensional structure
Solution Approach 1:
The patent transitions from a three-dimensional erected structure to a planar two-dimensional arrangement. The micro light emitting elements are placed horizontally on the stopper layer between electrodes rather than being erected vertically and connected through complex 3D structures, simplifying the overall device architecture while maintaining manufacturability
Data Source
AI summary
A display device includes a pixel circuit, a first insulation layer covering the pixel circuit, a first electrode disposed on the first insulation layer, a second electrode disposed on the first insulation layer while being spaced apart from the first electrode, a second insulation layer covering the first electrode, the second electrode, and the first insulation layer disposed between the first electrode and the second electrode, and a light emitting element electrically connected to the first electrode and the second electrode on the second insulation layer and disposed between the first electrode and the second electrode. Here, the second insulation layer includes a first area overlapping the first electrode, a second area overlapping the second electrode, and a stopper area disposed between the first electrode and the second electrode, and the stopper area has a thickness different from that of each of the first area and the second area.