Micro LED Insulating Film Structure to Prevent Agglomeration
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Solution Overview
Problem
Existing light emitting diodes (LEDs) face issues with agglomeration when fabricated in small sizes, leading to potential short-circuits and deterioration in display devices due to adjacent elements coming into contact.
Innovation Solution
The design includes an emission stacked pattern with a non-uniform thickness insulating film surrounding it, featuring varying shapes and protrusions to maintain separation between adjacent elements, preventing agglomeration and ensuring stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If LEDs are fabricated in small sizes to form display pixels, then the display resolution and density are improved, but adjacent LEDs may agglomerate and cause short-circuits
Solution Approach 1:
An insulating film is introduced as an intermediary between adjacent emission stacked patterns. This insulating film physically separates the conductive semiconductor structures, preventing direct contact and potential short-circuits while allowing the LEDs to be fabricated in small sizes for high-resolution displays.
Solution Approach 2:
The insulating film is selectively positioned between adjacent emission stacked patterns rather than uniformly throughout the entire structure. This localized application of insulation provides targeted separation where needed (between adjacent elements) while maintaining the compact overall structure required for high display resolution.
2Ease of manufacture
If the insulating film has uniform thickness, then the manufacturing process is simplified, but adjacent light emitting elements may still agglomerate
Solution Approach 1:
The insulating film is designed with non-uniform thickness, where the thickness varies in different regions. Specifically, the insulating film may be thicker in regions where adjacent emission stacked patterns are closer together, providing enhanced separation, while being thinner in regions where more separation is naturally available. This localized variation in thickness optimizes agglomeration prevention while remaining manufacturable.
Data Source
AI summary
A light emitting element includes an emission stacked pattern and an insulating film. The emission stack pattern includes a first conductive semiconductor layer, an active layer disposed on the first conductive semiconductor layer, and a second conductive semiconductor layer disposed on the active layer. The insulating film surrounds an outer surface of the emission stacked pattern and has a non-uniform thickness.