Pixel Electrode Structure for Self-Aligning Nano-LED Arrays
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Solution Overview
Problem
Existing pixel structures face challenges in efficiently aligning and connecting extremely small-sized LED elements to electrodes due to their nano-size, making direct physical connection difficult and prone to misalignment.
Innovation Solution
A pixel structure design featuring a base substrate with first and second electrodes, where a radial electric field is generated by applying different voltages to these electrodes, facilitating self-alignment and connection of LED elements between them, with a separation distance of 1 μm to 7 μm and voltage differences of 10 V to 50 V.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If direct physical connection method is used to connect nano-sized LED elements to electrodes, then manufacturing process is simple, but alignment precision deteriorates due to misalignment
Solution Approach 1:
The patent introduces an intermediary alignment structure consisting of a first electrode and a second electrode that act as mediators to guide and align the nano-sized LED elements during the connection process. This intermediary structure enables precise alignment without requiring direct manual positioning, thus maintaining manufacturing simplicity while improving alignment precision.
Solution Approach 2:
The patent replaces the mechanical direct connection method with an electric field-based alignment system. By applying voltage to the first and second electrodes, an electric field is generated that automatically aligns the LED elements through electrostatic forces, substituting mechanical positioning with a more precise field-based control mechanism.
2Productivity
If nano-sized LED elements are used to increase pixel density, then productivity is improved, but manufacturing precision deteriorates due to alignment difficulty
Solution Approach 1:
The first and second electrodes serve as intermediary alignment structures that guide the nano-sized LED elements into proper positions. These electrodes create a controlled environment that automatically positions the small LED elements, enabling high pixel density while maintaining precise alignment through the intermediary guiding structures.
Solution Approach 2:
The patent replaces mechanical alignment methods with an electric field-based system where voltage applied to the electrodes creates electrostatic forces that automatically position the nano-sized LED elements. This substitution enables precise alignment of high-density pixels without complex mechanical positioning systems.
3Manufacturing precision
If separation distance between electrodes is reduced to improve alignment, then manufacturing precision is improved, but device complexity increases due to tighter tolerances
Solution Approach 1:
The patent replaces mechanical tolerance control with an electric field-based alignment system. By applying voltage to the first and second electrodes, the system creates electrostatic forces that automatically align the LED elements, reducing the impact of physical tolerances and simplifying the overall device complexity despite small separation distances.
Solution Approach 2:
The patent changes the alignment mechanism from physical mechanical contact to electric field interaction. By controlling the voltage parameter applied to the electrodes, the system achieves precise alignment dynamically, reducing the need for tight physical tolerances and simplifying manufacturing complexity.
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 method effectively aligns and connects multiple nano-sized LED elements to electrodes, reducing misalignment rates and enabling intensive arrangement, thereby improving the luminous efficiency and reliability of the pixel structure.
Implementation Method 1
A radial electric field is generated by applying different voltages to these electrodes, facilitating self-alignment and connection of LED elements between them
Data Source
AI summary
A pixel structure, a display device, and a method of manufacturing a pixel structure, the pixel structure including a base substrate; at least one first electrode arranged in an upper portion of the base substrate; at least one second electrode having a circular shape extending along a circumferential direction around the at least one first electrode; and a plurality of LED elements connected to the first and second electrodes.