Micro LED Barrier Layer Segmentation for Alignment Stability
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Solution Overview
Problem
The alignment tolerances and patterning errors during the panel process of micro LED displays, particularly due to thermal expansion and bending of the substrate and barrier layer, result in misalignment of the micro LEDs, affecting brightness and assembly accuracy.
Innovation Solution
Incorporation of stress separation lines on the substrate, including compensation lines, to manage thermal expansion and prevent bending, ensuring precise alignment and reduced alignment errors by distributing stress effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a barrier layer is formed on the substrate and a curing process is performed, then the barrier layer is cured and provides protection, but the barrier layer expands due to thermal or ultraviolet curing, causing the assembly hole pattern to move and misalignment with the electrode
Solution Approach 1:
The barrier layer is divided into multiple segments by introducing stress separation lines that extend from the center of the substrate to the edges. These lines segment the barrier layer into radial sections, allowing each segment to expand independently during curing without causing overall pattern displacement. This segmentation resolves the contradiction by maintaining structural integrity and protection while preventing misalignment.
Solution Approach 2:
The stress separation lines are strategically positioned at specific radial distances from the substrate center, creating zones with different stress distribution characteristics. The local quality of the barrier layer is modified by these lines, which act as stress relief pathways in specific locations while maintaining barrier functionality in other areas, thus preventing expansion-induced misalignment.
2Productivity
If the substrate and barrier layer structure is formed during the panel process, then the display device is manufactured, but bending occurs in the structure due to thermal expansion, causing patterning errors at outer locations
Solution Approach 1:
The barrier layer is divided into multiple segments by introducing stress separation lines that extend from the center of the substrate to the edges. These lines segment the barrier layer into radial sections, allowing each segment to expand independently during curing without causing overall pattern displacement. This segmentation resolves the contradiction by maintaining structural integrity and protection while preventing misalignment.
Solution Approach 2:
The stress separation lines are strategically positioned at specific radial distances from the substrate center, creating zones with different stress distribution characteristics. The local quality of the barrier layer is modified by these lines, which act as stress relief pathways in specific locations while maintaining barrier functionality in other areas, thus preventing expansion-induced misalignment.
3Ease of manufacture
If micro LEDs are assembled using the barrier layer assembly holes, then the display device is constructed, but alignment tolerances cause deviations in micro LED position, affecting brightness or causing failure to light up
Solution Approach 1:
The barrier layer is divided into multiple segments by introducing stress separation lines that extend from the center of the substrate to the edges. These lines segment the barrier layer into radial sections, allowing each segment to expand independently during curing without causing overall pattern displacement. This segmentation resolves the contradiction by maintaining structural integrity and protection while preventing misalignment.
Solution Approach 2:
The stress separation lines are strategically positioned at specific radial distances from the substrate center, creating zones with different stress distribution characteristics. The local quality of the barrier layer is modified by these lines, which act as stress relief pathways in specific locations while maintaining barrier functionality in other areas, thus preventing expansion-induced misalignment.
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
The stress separation lines minimize alignment errors and maintain the position of assembly holes, enhancing the accuracy and reliability of micro LED display assembly by mitigating stress from thermal expansion and curing processes.
Implementation Method 1
Since this curing process is a high temperature process, the barrier layer may expand. Accordingly, the mounting space (assembly hole pattern) formed at the location where the light emitting device is to be mounted may be moved.
Data Source
AI summary
The present invention is applicable to display device-related technical fields and, for example, relates to a display device using micro LED (Light Emitting Diode) and a method of manufacturing the same. The present invention includes a substrate including a pixel area and a pad area located around the pixel area; a barrier layer located on the substrate and defining a plurality of unit pixel areas within the pixel area; a stress separation line located between the unit pixel areas on the barrier layer; a first electrode located in the unit pixel area; a semiconductor light emitting device in which a first type electrode is electrically connected to the first electrode within the unit pixel area; a coating layer formed on the semiconductor light emitting device and the barrier layer; and a second electrode electrically connected to the type second electrode of the semiconductor light emitting device on the coating layer.