Nano-scale LED Element with Metal Cap for Horizontal Assembly
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Solution Overview
Problem
Nano-scale LED elements face challenges in being individually arranged and mounted on target electrode regions due to size limitations, leading to difficulties in controlling the number of elements per unit area, positional alignment, and achieving high light output due to electrical shorts and poor connectivity.
Innovation Solution
A nano-scale LED element design with a first and second conductive semiconductor layer, an active layer, and a metal cap that extends from one end part to cover the side surface, featuring a partially curved outer surface, which facilitates easy alignment and increased surface area for electrical connection, allowing for improved self-alignment and connectivity when an electric field is applied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If nano-scale LED elements are mounted in a two-dimensional plane, then the number of elements per unit area is limited, but the light output quantity is insufficient
Solution Approach 1:
The patent transitions from two-dimensional planar arrangement to three-dimensional vertical stacking of LED elements. Multiple LED elements are stacked vertically along the light emission direction, enabling significantly higher element density per unit area while maintaining adequate light output through the stacked configuration.
2Manufacturing precision
If nano-scale LED elements are individually arranged and mounted on target electrode regions, then positional alignment can be controlled, but the mounting process is extremely difficult due to size limitations
Solution Approach 1:
Electrode patterns are pre-formed on the substrate before LED element placement. The electrodes extend in the light emission direction and are positioned in advance to receive and electrically connect with the LED elements, simplifying the subsequent mounting process while ensuring precise alignment.
Solution Approach 2:
The LED elements are designed with self-aligning features including protrusions that fit into corresponding recesses in the electrode structure. This self-alignment mechanism enables automatic positional correction during mounting, achieving precise alignment without complex manual positioning.
3Reliability
If nano-scale LED elements are connected to two different electrodes, then electrical connection can be established, but electrical shorts and poor connectivity occur frequently
Solution Approach 1:
Different regions of the LED element structure are assigned different electrical properties. The first and second electrodes have different potentials, and the LED element structure includes localized conductive and insulating regions that guide current flow through the active layer while preventing unwanted electrical shorts between electrodes.
Solution Approach 2:
The LED element structure includes intermediate insulating layers and protective coatings that mediate between the two electrodes. These intermediate structures prevent direct electrical contact between oppositely-polarized electrodes while maintaining proper electrical connection through the active LED layer.
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 design significantly increases the number of nano-scale LED elements per unit area, enhances electrical connectivity, and achieves a desired light output without faults, improving durability and luminous efficiency.
Implementation Method 1
when an electric field is applied
Implementation Method 2
nano-scale light-emitting diode (LED) element
Implementation Method 3
a semiconductor device that converts electronic signals into light having a desired wavelength band and emits the light
Data Source
AI summary
The present invention relates to a nano-scale light-emitting diode (LED) element for a horizontal array assembly, a manufacturing method thereof, and a horizontal array assembly including the same, and more particularly, to a nano-scale LED element for a horizontal array assembly that can significantly increase the number of nano-scale LED elements connected to an electrode line, facilitate an arrangement of the elements, and implement a horizontal array assembly having a very good electric connection between an electrode and an element and a significant high quantity of light when a horizontal array assembly having the nano-scale LED elements laid in a length direction thereof and connected to the electrode line is manufactured, a manufacturing method thereof, and a horizontal array assembly including the same.