Protruding Electrode Contact for LED Mounting Stability
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Solution Overview
Problem
Existing display apparatus manufacturing methods face challenges in accurately and stably mounting light-emitting diodes (LEDs) on substrates due to difficulties in achieving precise electrical connections and ensuring reliable contact between the LED contact electrodes and the substrate electrodes.
Innovation Solution
The solution involves a display apparatus design with a protruding portion of the first electrode member that extends into an opening of an insulating member surrounding the LED, where the opening's inner side surface has a first gradient and the protruding portion's outer side surface has a second gradient, equal to or less than the first gradient, allowing for stable and accurate contact with the LED's contact electrode, and a passivation layer is used to fill the space between the LED and the bank layer for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional flat electrode structure is used, then the manufacturing process is simple, but the electrical connection stability between LED and substrate is poor
Solution Approach 1:
The protruding portion is formed in advance on the first electrode before LED mounting, creating a pre-positioned contact structure that guides the LED's first contact electrode into proper alignment and ensures stable electrical connection upon mounting
2Measurement precision
If the opening in the insulating member is small, then the insulating performance is good, but the contact accuracy between LED and substrate electrode is reduced
Solution Approach 1:
The protruding portion acts as an intermediary element that extends from the first electrode through the opening of the insulating member to contact the first contact electrode, enabling accurate electrical connection while the insulating member maintains its insulating function around the contact electrode
3Reliability
If the gradients of the insulating member and protruding portion are not matched, then the manufacturing is easier, but the mounting stability and contact reliability are reduced
Solution Approach 1:
The gradient of the protruding portion's outer side surface is designed to be equal to or less than the gradient of the insulating member's inner side surface, creating a matched geometric relationship that ensures stable insertion and reliable contact while maintaining manufacturability
Data Source
AI summary
A display apparatus includes a display substrate including a first electrode member; and a light-emitting diode (“LED”) on the display substrate and connected to the first electrode member of the display substrate. The first electrode member includes: a first electrode, and a protruding portion which protrudes from an upper surface of the first electrode. The LED includes a p-n diode, a first contact electrode disposed at a side of the p-n diode, and an insulating member surrounding the first contact electrode and in which an opening is defined which exposes a surface of the first contact electrode. The protruding portion of the first electrode member extends into the opening of the light-emitting diode and is in contact with the exposed surface of the first contact electrode.