Plate-like LED Structure for Inkjet Self-Alignment
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Solution Overview
Problem
Current LED technologies face challenges in achieving high-resolution displays due to limitations in manufacturing processes, such as high unit prices, high defect rates, and low productivity, especially when aligning red, green, and blue micro-LEDs for 8K resolution displays, and existing self-alignment methods are costly and inefficient, with issues like LED element precipitation and reduced light emission efficiency.
Innovation Solution
An LED structure with a specific geometry and composition, including a first and second conductive semiconductor layer, a photoactive layer, and protective films, that allows for self-alignment without additional processes, optimizing electron-hole recombination and increasing the emission area, thereby improving luminous efficiency and ease of contact with electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If LED elements are aligned through an electric field using rod-like shape with large aspect ratio, then self-alignment is achieved, but the LED elements are easily precipitated in solvent and difficult to form into ink
Solution Approach 1:
The patent changes the geometric parameters of the LED element from a rod-like shape with large aspect ratio to a plate-like shape with specific area-to-thickness ratio (S/t ≥ 1.5). This parameter change allows the element to maintain self-alignment capability through gravitational settling while improving solubility and ink formation capability, resolving the contradiction between ease of operation and ease of manufacture.
2Ease of operation
If LED elements are assembled to lie down parallel to stack direction of semiconductor layers, then self-alignment is achieved, but the area from which light is extracted is small causing low efficiency
Solution Approach 1:
The patent introduces asymmetry in the assembly orientation by specifying that the normal vector of the first target surface should form an angle of 0° to 30° with the normal vector of the electrode surface, rather than requiring perfect parallel alignment. This asymmetric angular range allows the large-area surface to face the electrode for optimal light extraction while still achieving effective self-alignment through gravitational settling.
3Ease of operation
If power is applied to electrodes to align LED elements through electric field, then self-alignment is achieved, but the electrodes may be damaged by high voltage power source
Solution Approach 1:
The patent extracts and removes the electric field alignment mechanism from the process, replacing it with gravitational settling-based self-alignment. By taking out the high voltage power source requirement, the method achieves self-alignment without exposing electrodes to damaging high voltage, thus resolving the contradiction between ease of operation and protection from harmful factors.
4Ease of operation
If additional processing such as magnetic layer on LED element is used for magnetic self-alignment, then self-alignment is achieved, but manufacturing cost and time increase
Solution Approach 1:
The patent enables the LED element to self-align through gravitational settling based on its own geometric properties (plate-like shape with S/t ≥ 1.5), without requiring any additional magnetic layers or external magnetic field generation devices. This self-service approach resolves the contradiction by achieving self-alignment through the element's intrinsic geometry rather than added 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
The proposed LED structure enhances luminous efficiency by optimizing electron-hole recombination and increasing the emission area, simplifying the self-alignment process, and reducing manufacturing costs, making it suitable for high-resolution displays without the need for additional alignment processes.
Implementation Method 1
optimizes the recombination rate of electron-holes
Data Source
AI summary
The present invention relates to an LED structure, more particularly, to an LED structure and an ink for inkjet and light source including the same.