Self-Assembled Monolayer Adhesive for LED Substrate Bonding
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Solution Overview
Problem
The bonding force between light emitting diodes (LEDs) and substrates in display devices is often compromised by metal corrosion or out-gassing due to residual flux used in coating processes, leading to lighting defects.
Innovation Solution
A display device with an adhesive auxiliary layer comprising a self-assembled monolayer, specifically a siloxane compound, is used to improve the bonding force between the LEDs and the substrate, eliminating the need for a flux coating process and minimizing lighting defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flux coating process is used to improve bonding force between light emitting diode and substrate, then bonding force is improved, but metal corrosion or out-gassing occurs due to residual flux
Solution Approach 1:
The patent introduces an adhesive auxiliary layer as an intermediary between the light emitting diode and the substrate. This layer consists of a self-assembled monolayer formed by siloxane compounds that chemically bond to both the LED pad and the substrate, providing strong adhesion without requiring flux coating. The intermediary layer eliminates direct contact between flux and metal components, preventing corrosion while maintaining bonding strength.
Solution Approach 2:
The patent changes the chemical and physical parameters of the bonding interface by using self-assembled monolayers with specific molecular structures. The siloxane compounds form controlled chemical bonds (Si-O-Si) with the substrate and organic bonds with the LED pad, creating an optimized bonding interface that achieves strong adhesion without the harmful effects of traditional flux materials.
2Strength
If a flux coating process is used to improve bonding force between light emitting diode and substrate, then bonding force is improved, but lighting defects occur due to out-gassing
Solution Approach 1:
The adhesive auxiliary layer serves as a protective intermediary that prevents out-gassing from reaching the light emitting diode. The self-assembled monolayer acts as a barrier layer that blocks residual flux decomposition products from migrating to the LED, thereby preventing lighting defects while still allowing strong bonding to occur at the interface.
Solution Approach 2:
The patent addresses out-gassing issues by creating a sealed bonding interface through the self-assembled monolayer. This layer forms a protective barrier that prevents gas molecules from penetrating through the bonding interface and reaching the light emitting diode, effectively blocking the harmful effects of out-gassing.
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 self-assembled monolayer enhances the bonding force between the LEDs and the substrate, preventing metal corrosion and out-gassing, thus reducing lighting defects and improving the overall performance of the display device.
Implementation Method 1
an adhesive auxiliary layer disposed on the first electrode and including a self-assembled monolayer
Implementation Method 2
The adhesive auxiliary layer may form a silicon-oxygen (Si—O) bond with a surface of the first electrode
Data Source
AI summary
A display device and a method of manufacturing the same are provided. The display device includes a first electrode disposed on a substrate, an adhesive auxiliary layer disposed on the first electrode and including a self-assembled monolayer, a light emitting element disposed on the adhesive auxiliary layer, and a contact electrode disposed between the adhesive auxiliary layer and the light emitting element. The light emitting element includes a first semiconductor layer, a second semiconductor layer disposed on the first semiconductor layer, and an intermediate layer disposed between the first semiconductor layer and the second semiconductor layer.