Micro LED Coupling Structure for Stable Electrode Height Mismatch
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Solution Overview
Problem
Existing methods for coupling micro LEDs to array substrates face challenges in securing stable connections due to variations in electrode heights and complexity in manufacturing processes.
Innovation Solution
A display device design featuring columnar conductors made of harder materials than the coupling members, with specific configurations to ensure stable electrical connections between anode and cathode electrodes, and the use of conductive particles with varying sizes to enhance coupling stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive coupling posts are formed in the light-emitting diodes, then electrical connection is achieved, but the process of transferring the light-emitting diodes to the array substrate becomes complicated
Solution Approach 1:
The patent introduces a coupling member as an intermediary component between the light-emitting element and the array substrate. This coupling member includes a softer material layer that facilitates the bonding process and ensures reliable electrical connection without complicating the transfer procedure. The softer material acts as a mediator that enables stable coupling while simplifying the overall manufacturing process.
2Ease of manufacture
If an anisotropic conductive film is used to couple light-emitting diodes, then the coupling process is simplified, but coupling stability becomes difficult to secure when anode and cathode electrodes are at different height positions
Solution Approach 1:
The patent applies local quality by providing a coupling member with different material properties at different locations. The coupling member includes a softer material layer specifically positioned to contact the light-emitting element, while the mounting electrode on the array substrate provides structural support. This localized differentiation in material properties ensures stable coupling even when electrodes are at different heights, while maintaining ease of manufacture.
3Ease of manufacture
If coupling members are made of softer material to facilitate bonding, then ease of coupling is improved, but resistance to mechanical stress and potential for short circuits increases
Solution Approach 1:
The patent employs composite materials in the coupling member structure. The coupling member comprises a softer material layer (such as resin or polymer) combined with conductive particles or a conductive layer. This composite structure provides both the ease of coupling facilitated by the softer material and the short circuit resistance provided by the conductive components with appropriate mechanical strength.
Data Source
AI summary
A display device includes an array substrate, a plurality of mounting electrodes provided to the array substrate, a columnar conductor for coupling provided to each of the mounting electrodes, a plurality of light-emitting elements provided to the array substrate, a first electrode and a second electrode provided to a surface of each of the light-emitting elements facing the array substrate, the first electrode being coupled to one of an anode and a cathode of the light-emitting element, the second electrode being coupled to the other of the anode and the cathode of the light-emitting element, and a coupling member covering each of the first electrode and the second electrode. The columnar conductor is made of material harder than the coupling member, and an end of the columnar conductor on the light-emitting element side is electrically coupled to the coupling member.