Micro LED Pixel Alignment with Magnetic-Capillary Assembly
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Solution Overview
Problem
Existing display technologies, such as LCDs and OLEDs, face challenges with slow response time, high energy consumption, and short lifespan, while micro LED displays struggle with accurate alignment due to weak capillary forces, leading to low yield and inefficiency.
Innovation Solution
A display device with a lower substrate featuring a magnetic portion and reaction portion, where light-emitting devices are aligned using a combination of capillary and magnetic forces, allowing for precise alignment and reduced defects, and utilizing inorganic materials for improved efficiency and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If micro LEDs are self-aligned by capillary force alone, then the alignment process is simple, but the alignment accuracy is insufficient and many micro LEDs are wasted
Solution Approach 1:
The patent combines capillary force and magnetic force into a unified alignment system. The lower electrode includes both a capillary portion (for liquid infiltration and capillary action) and a magnetic portion (for magnetic attraction), working together to achieve precise alignment of micro LEDs without wasting components.
Solution Approach 2:
The lower electrode is constructed as a composite structure integrating capillary material and magnetic material. This composite design allows the electrode to simultaneously provide capillary action for positioning and magnetic force for secure alignment, resolving the contradiction between process simplicity and alignment precision.
2Reliability
If one micro LED is aligned in one pixel region, then the display quality should be good, but a plurality of micro LEDs may be arranged in one pixel region causing defects
Solution Approach 1:
The patent applies different local properties to different regions of the lower electrode. The capillary portion provides localized positioning guidance, while the magnetic portion provides localized attraction force. This local differentiation ensures that each micro LED aligns precisely with its designated pixel region, preventing multiple LEDs from occupying the same region.
3Adaptability or versatility
If organic materials are used in OLED displays, then the device can be formed on flexible substrates with excellent color capability, but the lifetime is short and mass-production yield is low
Solution Approach 1:
The patent replaces organic light-emitting materials with inorganic micro LED materials. This substitution eliminates the lifetime and yield problems associated with organic materials while maintaining the ability to achieve excellent color capability and flexibility through the micro LED structure and device design.
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
This approach enables accurate and efficient alignment of light-emitting devices, reduces defective connections, and achieves high-speed response with excellent luminance and long lifespan, eliminating the need for a separate backlight unit.
Implementation Method 1
a magnetic portion disposed on the lower substrate and having magnetic properties, and a reaction portion disposed at each of the light-emitting devices and forming an attractive force with the magnetic portion
Implementation Method 2
micro LEDs are self-aligned to a lower wiring by a capillary force
Data Source
AI summary
Discussed is a display device, including a substrate, a substrate electrode disposed on the substrate, a magnetic portion disposed and having a magnetic property on an upper surface of the substrate, and a plurality of light-emitting devices respectively disposed on the magnetic portion, wherein the each of the plurality of light-emitting devices includes a magnetic electrode forming an attractive force with the magnetic portion.