Micro-LED Lateral Electrode Mesh Wiring for Mounting
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Solution Overview
Problem
The manufacturing of micro-LED display devices is hindered by the difficulty in mounting light-emitting elements onto substrates due to the need for both high electrical conductivity and high light transmissivity on the upper surface, leading to increased costs.
Innovation Solution
A method involving a substrate with sub-pixels and first wiring, where the light-emitting element has a semiconductor with a lower surface and intersecting lateral surfaces, with a first electrode on the lower surface and a second electrode on the lateral surfaces, covered by a resin member, and a second wiring with a mesh shape is formed to connect to the second electrode, allowing for easier electrical connection and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the upper surface of the light-emitting element is used for both electrical connection and light extraction, then both electrical conductivity and light transmissivity are required, but mounting becomes difficult and manufacturing cost increases
Solution Approach 1:
The patent moves the second electrode from the upper surface to the lateral surfaces of the light-emitting element. This dimensional change allows the upper surface to be dedicated to light extraction while lateral surfaces provide electrical connection, resolving the conflict between electrical conductivity and light transmissivity requirements.
Solution Approach 2:
The patent divides the electrical connection function into two separate electrodes: first electrode on the lower surface for mounting connection, and second electrode on the lateral surfaces for additional electrical connection. This segmentation allows each surface to have optimized functionality without compromising the other.
2Ease of manufacture
If the second electrode is exposed from the resin member, then electrical connection to the second wiring is enabled, but the resin member structure becomes more complex
Solution Approach 1:
The patent uses the lateral surfaces of the light-emitting element as an intermediary structure. The second electrode is formed on these lateral surfaces, which naturally protrude through the resin member, providing automatic exposure without requiring complex resin structuring or additional exposure processes.
3Manufacturing precision
If micro-LEDs are used for pixels, then higher resolution and contrast are achieved, but mounting difficulty increases manufacturing cost
Solution Approach 1:
By moving the second electrode to lateral surfaces, the patent enables simpler mounting processes for micro-LEDs. The lateral surface electrodes can be connected to second wirings on the substrate without requiring precise alignment on the tiny upper surface, making micro-LED mounting more feasible and cost-effective.
Data Source
AI summary
A method of manufacturing a display device 1 includes: providing a substrate including at least one sub-pixel defined therein and a first wiring disposed for the sub-pixel, and the light-emitting element that includes a first electrode disposed on a lower surface and a second electrode disposed on at least two lateral surfaces intersecting with each other; mounting the light-emitting element on the substrate and electrically connecting the first electrode to the first wiring; forming a resin member covering the at least one light-emitting element, on the substrate, exposing a portion of the second electrode from an upper surface of the resin member by removing an upper portion of the resin member; and forming a second wiring with a mesh shape on the resin member such that a portion of the second wiring is disposed on the light-emitting element to electrically connect the second wiring to the second electrode.