Patterned LED Electrode Structure for Uniform Pixel Emission
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Solution Overview
Problem
Existing inorganic light-emitting diode (LED) manufacturing processes, such as those using dielectrophoresis, are limited in producing LEDs with high durability and efficiency, particularly in achieving uniform light-emitting characteristics across pixels in display devices.
Innovation Solution
A light-emitting element with different roughness on its end surfaces and a protrusion pattern formed on the electrode layer, manufactured through a method involving multiple etching processes to create semiconductor rods with specific protrusion patterns, which helps in identifying and controlling light-emitting characteristics by adjusting the composition ratios based on the pattern positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional dielectrophoresis (DEP) method is used for manufacturing inorganic LEDs, then the manufacturing process is simple, but the durability and efficiency of the LEDs are limited
Solution Approach 1:
The patent applies preliminary action by forming protrusion patterns on the electrode layer before assembling the light-emitting element. These pre-formed patterns create controlled interfaces that improve carrier injection and recombination efficiency, leading to enhanced LED durability and efficiency without requiring complex manufacturing processes during assembly
Solution Approach 2:
The patent implements local quality by creating protrusion patterns at specific locations on the electrode layer surface. These localized structural modifications concentrate electrical fields and improve carrier injection at critical interfaces, thereby enhancing overall device performance through targeted local improvements rather than uniform changes throughout the entire structure
2Manufacturing precision
If protrusion patterns are formed on the electrode layer, then light-emitting characteristics are precisely controlled, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the electrode layer surface into distinct regions with protrusion patterns. This segmentation allows independent optimization of different areas for specific functions such as carrier injection, light extraction, and thermal management, enabling precise control of light-emitting characteristics through localized pattern design
Solution Approach 2:
The patent implements parameter changes by systematically varying the geometric parameters of the protrusion patterns (such as height, width, spacing, and arrangement) to optimize light-emitting characteristics. By adjusting these physical parameters, the patent achieves precise control over electrical field distribution, carrier injection efficiency, and light extraction properties
3Manufacturing precision
If different roughness patterns are created on end surfaces, then uniform light-emitting characteristics across pixels are achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies universality by designing protrusion patterns that simultaneously achieve multiple functions: they control interface morphology for uniform light emission, facilitate carrier injection, enhance light extraction, and provide mechanical alignment features. This multi-functionality allows a single manufacturing step to address multiple requirements, maintaining productivity while achieving uniform characteristics across pixels
Data Source
AI summary
A light-emitting element, a method for manufacturing same, and a display device are provided. The light-emitting element comprises: a first semiconductor layer and a second semiconductor layer; an active layer between the first semiconductor layer and the second semiconductor layer; and an electrode layer on the second semiconductor layer and having a first surface and a second surface facing the first surface, the second surface contacting the second semiconductor layer. The electrode layer includes a first protruding pattern in which at least a partial area of the first surface protrudes.