RGB Pixel Unit Electrode Layout for Narrow Wiring Spacing
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Solution Overview
Problem
Existing LED display technologies face challenges in achieving narrow spacings between wirings for micro and mini LED chips, leading to uneven shapes and potential misalignment of light-emitting diode chips during attachment, which affects the resolution and yield of the displays.
Innovation Solution
A pixel unit design utilizing laser cutting to form electrode wires with blocking wall structures, allowing for narrower spacings between electrode wires and ensuring precise alignment of light-emitting elements through the use of blocking wall structures formed during the laser cutting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional etching method is used to form wirings, then the wiring can be formed on substrate, but the spacing between wirings is not narrow enough and the wiring shape is uneven
Solution Approach 1:
The patent replaces the traditional mechanical etching process with a laser-based formation method. The laser directly writes the wiring patterns and blocking wall structures without requiring chemical etching, achieving narrower spacing and more uniform shapes while simplifying the manufacturing process.
Solution Approach 2:
The blocking wall structures are formed simultaneously with the wiring during the laser writing process, before the light-emitting elements are attached. This preliminary formation of positioning structures ensures precise alignment and prevents misalignment during subsequent assembly steps.
2Reliability
If light-emitting diode chips are attached to wirings formed by etching, then the chips can be mounted, but the chips may be misaligned due to uneven wiring shapes
Solution Approach 1:
The blocking wall structures serve as intermediary positioning elements between the wirings and the light-emitting elements. These walls provide physical guides that ensure accurate alignment during chip attachment, eliminating the misalignment problems caused by uneven wiring shapes in traditional etching methods.
Solution Approach 2:
The blocking wall structures are formed in advance during the laser wiring process, creating precise positioning features before the light-emitting elements are attached. This preliminary positioning ensures that subsequent chip placement is accurate and consistent.
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 laser cutting method reduces line spacings, lowers production costs, and enhances the yield of the pixel unit by maintaining consistent contact between light-emitting elements and electrode wires, thereby improving the resolution and reliability of LED displays.
Implementation Method 1
A pixel unit and a manufacturing method thereof... utilizing laser cutting to form electrode wires with blocking wall structures
Data Source
AI summary
A pixel unit includes a substrate, a wiring layer and three light-emitting elements. The wiring layer includes first electrode wires and second electrode wires. The first electrode wires and the second electrode wires are arranged side by side and separated from each other by a spacing. A first blocking wall structure is at a first end portion of each of the first electrode wires, the first end portion is near the corresponding second electrode wires, and a second blocking wall structure is at a second end portion of each of the second electrode wires, the second end portion is near the corresponding first electrode wires. Three light-emitting elements emit red light, green light and blue light respectively. The light-emitting elements are in a flip chip configuration and are connected to one of the first electrode wires and one of the second electrode wires adjacent to each other respectively.