Pixel Electrode Layout for Aligning Subminiature Light Emitters
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Solution Overview
Problem
Current display device manufacturing techniques are complex and inefficient, particularly in the integration and alignment of subminiature light emitting elements, which hinders the simplification of the fabrication process.
Innovation Solution
A display device and method of fabrication that utilize a simplified process for integrating subminiature light emitting elements, including a rod-type or core-shell light emitting element with an insulating film, and a switch unit with alignment signals to align the light emitting elements during fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing techniques are used for integrating subminiature light emitting elements, then the fabrication process can be completed, but the process becomes complex and inefficient
Solution Approach 1:
The patent applies preliminary action by pre-forming the light emitting elements with integrated electrode structures and pre-aligning them using alignment marks before final integration. The elements are prepared in advance with built-in alignment features that simplify the subsequent integration process, avoiding complex real-time alignment procedures.
Solution Approach 2:
The patent uses an intermediary approach by introducing alignment marks and intermediate bonding layers that facilitate the integration process. These intermediaries serve as reference points and coupling media that simplify the alignment and bonding of light emitting elements to the substrate, reducing the overall process complexity.
2Manufacturing precision
If subminiature light emitting elements are integrated with high precision alignment, then the display quality is improved, but the manufacturing efficiency decreases
Solution Approach 1:
The patent implements self-service by designing light emitting elements with self-aligning features such as asymmetric electrode configurations and integrated alignment marks. These features enable the elements to automatically position themselves relative to the substrate and other elements during the bonding process, achieving high precision alignment without requiring complex external alignment equipment or procedures.
Solution Approach 2:
The patent applies preliminary action by pre-forming alignment marks and reference structures on both the light emitting elements and the substrate before the bonding step. This preliminary preparation enables rapid automated alignment using optical detection systems, significantly improving manufacturing efficiency while maintaining high precision.
3Reliability
If multiple fabrication steps are used for integrating light emitting elements, then the integration quality is improved, but the fabrication process becomes inefficient
Solution Approach 1:
The patent merges multiple fabrication steps into fewer integrated operations. Specifically, it combines the alignment, bonding, and electrical connection steps into a single integrated process by using pre-formed electrode structures that serve both as electrical contacts and as alignment references. This merging reduces the total number of process steps while maintaining integration quality.
Solution Approach 2:
The patent applies multi-functionality by designing structural features that serve multiple purposes simultaneously. For example, the electrode structures serve both as electrical contacts and as alignment references, while certain layers serve both as protective coatings and as bonding interfaces. This multi-functionality reduces the number of separate fabrication steps required.
Data Source
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Figure 4A~4B
AI summary
A display device in accordance with an embodiment of the present disclosure includes: a pixel disposed in a display area; a first line connected to the pixel; and a first control line disposed around the first line. The pixel includes: a first electrode and a second electrode spaced apart from each other; at least one intermediate electrode including a first intermediate electrode between the first electrode and the second electrode; a plurality of light emitting elements respectively connected between a pair of adjacent electrodes among the first electrode, the second electrode, and the at least one intermediate electrode; and a first switching element connected between the first intermediate electrode and the first line, and configured to be controlled by a signal applied to the first control line.