Nanowire LED Defect Isolation via Photosensitive Resin
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Solution Overview
Problem
The manufacturing process of light-emitting diodes (LEDs) using nanowires is hindered by the presence of defective nanowires, which can cause short-circuits and structural defects, leading to malfunctions and poor reproducibility due to their large number and potential for absorbing radiation, thus affecting the overall performance and reliability of the LEDs.
Innovation Solution
A method is developed to isolate defective nanowires by using negative and positive photosensitive resins sensitive to specific wavelengths, where active nanowires emit radiation to reduce the solubility of the resin, allowing for the identification and removal of defective wires, thereby ensuring only functional nanowires remain connected electrically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large number of nanowires are used to increase emission surface and luminous flux, then the luminous flux increases, but the probability of defective nanowires increases leading to poor reproducibility and malfunctions
Solution Approach 1:
The patent applies preliminary action by performing defect detection and isolation before final device assembly. The photosensitive resin is applied and activated early in the process to mark defective nanowires, allowing them to be identified and removed before they can cause malfunctions in the final LED device. This proactive approach prevents defective nanowires from compromising the reliability of the final product.
Solution Approach 2:
The patent extracts defective nanowires from the ensemble by using photosensitive resin that selectively adheres to defective regions. The resin is activated by radiation to reduce solubility specifically at defective sites, allowing defective nanowires to be distinguished and removed from the functional nanowire array, thereby maintaining high reliability while preserving the beneficial effects of having many nanowires.
2Ease of manufacture
If conventional manufacturing processes are used without defect isolation, then the manufacturing process is simple, but defective nanowires cause short-circuits and malfunctions
Solution Approach 1:
The patent introduces an intermediary substance - the photosensitive resin - that mediates between the manufacturing process and the defective nanowires. This resin acts as a marker that selectively binds to defective regions when activated by radiation, enabling easy identification and removal of harmful defective nanowires without complicating the overall manufacturing process. The intermediary allows for selective manipulation of defective elements while leaving functional nanowires unaffected.
3Reliability
If photosensitive resin is applied to isolate defective nanowires, then defective nanowires can be removed, but additional manufacturing steps are required
Solution Approach 1:
The patent replaces complex mechanical or manual inspection and isolation methods with a chemical-optical system. Instead of physically examining each nanowire or using complex mechanical sorting devices, the process uses photosensitive resin chemistry activated by radiation to automatically mark defective nanowires. This substitution of mechanical inspection with a chemical field-based method reduces the apparent complexity of the isolation step while maintaining high reliability.
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 process enhances the reproducibility and reliability of LEDs by effectively isolating defective nanowires, increasing the luminous flux and reducing the risk of malfunctions, resulting in higher-quality light-emitting diodes with improved manufacturing efficiency.
Implementation Method 1
activating all of said nanowires under electrical control or under optical control so that said active nanowires emit said radiation towards said resin, said radiation reducing the solubility of said negative resin
Implementation Method 2
producing a layer of negative photosensitive resin, sensitive to said emission wavelength λ, covering all of said nanowires; activating all of said nanowires under electrical control or under optical control so that said active nanowires emit said radiation towards said resin, said radiation reducing the solubility of said negative resin
Data Source
AI summary
The invention concerns a method for producing a set of nanowires (NTn) on the surface of a substrate, said nanowires having a portion capable of emitting radiation on at least one wavelength (λ) under the action of an electrical or optical control and being at least partially connected to each other electrically via an upper conductive layer (60), characterised in that it comprises steps allowing the identification of a sub-set of faulty nanowires (NTi) among the active nanowires (NTj), said steps comprising: - the production of a layer of negative photosensitive resin, sensitive to said emission wavelength (λ), covering all of said nanowires; - the activation of all of said nanowires under electrical control or optical control such that said active nanowires emit said radiation, said radiation reducing the solubility of said negative resin; - the development of said resin at the faulty nanowires (NTi), leaving areas that are made less soluble and surrounding said active nanowires (NTj); - removing said conductive layer above said faulty nanowires. The invention also concerns a method for producing electroluminescent diode(s) using the method of the invention.