Segmented Conductive Layer Layout for Large-Area LED Displays
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Solution Overview
Problem
The existing methods for transferring semiconductor light emitting devices onto a wiring electrode using an anisotropic conductive layer often result in poor contact between the device and the electrode, especially as the area of the wiring substrate increases.
Innovation Solution
A display device structure and manufacturing method that incorporates a substrate with a wiring electrode, semiconductor light emitting devices electrically connected to the wiring electrode, and an anisotropic conductive layer made of a mixture of conductive particles and an insulating material. The anisotropic conductive layer is formed to surround individual or adjacent semiconductor light emitting devices, and a light-transmitting layer is introduced between the devices to enhance contact and prevent conductive particle separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an anisotropic conductive layer is used to transfer semiconductor light emitting devices onto a wiring electrode, then electrical connection between the device and electrode is achieved through thermal compression, but poor contact occurs when the area of the wiring substrate increases
Solution Approach 1:
The anisotropic conductive layer is divided into multiple separate anisotropic conductive layers, each positioned at specific locations corresponding to individual semiconductor light emitting devices or groups of devices. This segmentation ensures that each conductive layer maintains effective contact pressure with its corresponding device, preventing the contact reliability degradation that occurs in large-area substrates when using a single continuous conductive layer.
2Area of stationary object
If the area of the wiring substrate increases, then the display device can cover larger areas, but contact between the semiconductor light emitting device and the wiring electrode deteriorates
Solution Approach 1:
Instead of using a uniform continuous anisotropic conductive layer across the entire substrate, the invention applies discrete anisotropic conductive layers only at specific locations where semiconductor light emitting devices are positioned. This local quality approach ensures that contact precision is maintained at each device location regardless of the overall substrate size, as each discrete conductive layer is optimized for its specific contact point rather than being diluted across a large area.
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 approach minimizes the flow of the anisotropic conductive layer during pressing, ensuring consistent contact between the semiconductor light emitting devices and the wiring electrodes, thereby preventing contact failures and maintaining uniform pressure across the substrate.
Implementation Method 1
The use of the anisotropic conductive layer has an advantage in that the semiconductor light emitting device and the wiring electrode can be electrically connected only by thermal compression
Implementation Method 2
This approach minimizes the flow of the anisotropic conductive layer during pressing, ensuring consistent contact between the semiconductor light emitting devices and the wiring electrodes, thereby preventing contact failures and maintaining uniform pressure across the substrate
Implementation Method 3
a light-transmitting layer formed between the semiconductor light emitting devices
Data Source
AI summary
The present invention provides a display device including a substrate, a wiring electrode disposed on the substrate, and a plurality of semiconductor light emitting devices electrically connected to the wiring electrode, an anisotropic conductive layer disposed between the semiconductor light emitting devices and made of a mixture of conductive particles and an insulating material, and a light transmitting layer formed between the semiconductor light emitting devices. And the anisotropic conductive layer is formed in plurality, and any one of the plurality of anisotropic conductive layers is formed to surround one semiconductor light emitting device or to surround a plurality of semiconductor light emitting devices adjacent to each other.