Micro-LED Display Assembly with Blocking Members for Pixel Alignment
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Solution Overview
Problem
The assembly of light emitting devices in small-sized pixels is challenging due to random alignment, leading to high defect rates and low luminous efficiency, as some devices are misaligned or not connected to electrodes, resulting in non-functional light emission.
Innovation Solution
A display device design incorporating a substrate with blocking members and insulating layers to control the assembly direction of light emitting devices, using a plate-shaped structure with a major axis aligned for stable placement in assembly holes, enhancing surface contact and uniform light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light emitting devices are randomly dropped onto the substrate using self-assembly method, then the manufacturing process is simple and fast, but the assembly precision is poor resulting in misalignment and high defect rate
Solution Approach 1:
The patent applies preliminary action by pre-forming protrusions on the light emitting device that correspond to recesses in the substrate before assembly. This pre-matching geometry ensures that when devices are dropped onto the substrate, they automatically align correctly with the electrodes, eliminating misalignment issues while maintaining the simplicity of the self-assembly drop method
Solution Approach 2:
The patent introduces protrusions and recesses as intermediary geometric features that mediate between the light emitting device and substrate. These features act as mechanical guides that ensure proper orientation and alignment during the assembly process, solving the precision problem without complicating the manufacturing method
2Measurement precision
If the size of light emitting devices is reduced to micro or nano scale for high resolution, then the display resolution is improved, but the difficulty of aligning and transferring these devices increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming protrusions on the light emitting device that correspond to recesses in the substrate before assembly. This pre-matching geometry ensures that when devices are dropped onto the substrate, they automatically align correctly with the electrodes, eliminating misalignment issues while maintaining the simplicity of the self-assembly drop method
Solution Approach 2:
The patent applies self-service through self-alignment mechanisms where the protrusions on the light emitting device automatically find and fit into the recesses on the substrate during the dropping process. This self-aligning feature eliminates the need for complex external alignment equipment, making the transfer of micro/nano-scale devices feasible
Data Source
AI summary
The display device includes a substrate, a first wiring line on the substrate, a second wiring line on the substrate, and a first insulating member on the first wiring line and the second wiring line, a blocking member disposed across the first wiring line and the second wiring line, a second insulating member including a plurality of assembly holes, and a plurality of light emitting devices disposed in each of the plurality of assembly holes.Each of the plurality of assembly holes includes a first region closer to the blocking member and a second region farther than the first region from the blocking member. A part of the blocking member is disposed in the first area of the assembly hole.