Micro-LED Electrode Layout With Partition Walls for Precise Bonding
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Solution Overview
Problem
The challenge of bonding defects between ultraminiature LEDs and electrodes when separately manufacturing and connecting them is significant, making it difficult to arrange ultraminiature LEDs on electrodes effectively.
Innovation Solution
A display device design that includes first and second electrodes with partition walls and connection electrodes, where the LEDs are aligned between the electrodes using an electric field, and partition walls are designed to maintain LED positioning and prevent misalignment, with a capping layer enhancing light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultraminiature LEDs are separately manufactured and then connected to electrodes, then manufacturing flexibility is improved, but bonding defects increase and arrangement difficulty worsens
Solution Approach 1:
The patent introduces a binder as an intermediary substance to attach ultraminiature LEDs to the electrode. The binder fills the gaps between the tiny LED and electrode surface, ensuring complete coverage and reliable electrical connection. This mediator resolves the bonding defect issue by providing a reliable interface between the separately manufactured LED and electrode components.
Solution Approach 2:
The patent applies preliminary actions by pre-forming the electrode structure with integrated bonding surfaces and pre-mixing the binder material before LED attachment. The electrode is prepared in advance with appropriate surface properties to receive the ultraminiature LEDs, and the binder is pre-prepared to ensure optimal adhesion and electrical contact when the LEDs are attached.
2Ease of manufacture
If ultraminiature LEDs are separately manufactured and then connected to electrodes, then manufacturing flexibility is improved, but arrangement precision deteriorates
Solution Approach 1:
The binder serves as a positioning intermediary that fills the space between the ultraminiature LED and electrode, preventing misalignment. The binder material is applied in a controlled manner to ensure the LED is held in the precise correct position, thereby improving arrangement precision while maintaining manufacturing flexibility.
3Length of moving object
If electrode interval is reduced to accommodate smaller LEDs, then device miniaturization is improved, but LED placement difficulty increases
Solution Approach 1:
The binder acts as a compensating intermediary that allows for reliable LED attachment even when the electrode interval is reduced. The binder fills the reduced space between electrodes, ensuring proper LED positioning and electrical connection despite the smaller dimensions, thus enabling device miniaturization without significantly increasing placement difficulty.
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 solution reduces bonding defects and ensures stable electrical connections between ultraminiature LEDs and electrodes, improving the reliability and efficiency of the display device.
Implementation Method 1
the LEDs are aligned between the electrodes using an electric field
Data Source
AI summary
A display device includes a substrate, a first electrode extending in a first direction on the substrate, a first partition wall extending in the first direction on a central portion of the first electrode, a second electrode extending in parallel with the first electrode on the substrate, a second partition wall extending in the first direction on a central portion of the second electrode, and a plurality of light-emitting diodes electrically connected between the first electrode and the second electrode.