Spacer Opening Layout for Precise LED Transfer and Light Isolation

Solution Overview

Problem

The existing methods for transferring light-emitting units, such as LEDs, in electronic device manufacturing face challenges in achieving precise positioning and reducing light mixing between adjacent elements, leading to insufficient display quality and increased costs due to inefficient transfer processes.

Innovation Solution

The use of a spacer structure on the substrate with distinct regions and openings allows for precise positioning of light-emitting elements, separating them to prevent light mixing and enabling selective repair of subpixel regions, thereby reducing the number of elements that need to be transferred and lowering costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional transfer methods are used for light-emitting units, then the transfer process is simple, but positioning precision is insufficient and light mixing occurs between adjacent elements

Engineering Contradiction:

Improvepositioning precisionVSAvoidtransfer process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The substrate is divided into multiple regions (first region, second region, third region) separated by spacers, with each region containing specific openings for light-emitting units. This segmentation enables precise positioning of individual elements while preventing light mixing between adjacent regions, directly resolving the positioning precision issue without requiring complex external positioning mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spacers serve as intermediary structures between adjacent regions, physically separating them and preventing light from one region from mixing with adjacent regions. The spacers with varying widths act as mediators that define precise boundaries for light-emitting unit placement, achieving accurate positioning while maintaining a relatively simple transfer process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If adjacent light-emitting elements are placed close together, then device density increases, but light mixing occurs reducing display quality

Engineering Contradiction:

Improvedevice densityVSAvoidlight mixing

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The substrate is divided into multiple regions (first region, second region, third region) separated by spacers, with each region containing specific openings for light-emitting units. This segmentation enables precise positioning of individual elements while preventing light mixing between adjacent regions, directly resolving the positioning precision issue without requiring complex external positioning mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spacers serve as intermediary structures between adjacent regions, physically separating them and preventing light from one region from mixing with adjacent regions. The spacers with varying widths act as mediators that define precise boundaries for light-emitting unit placement, achieving accurate positioning while maintaining a relatively simple transfer process.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If all light-emitting elements are transferred and inspected, then defect detection is thorough, but manufacturing cost increases

Engineering Contradiction:

Improvedefect detection completenessVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The substrate is divided into multiple regions (first region, second region, third region) separated by spacers, with each region containing specific openings for light-emitting units. This segmentation enables precise positioning of individual elements while preventing light mixing between adjacent regions, directly resolving the positioning precision issue without requiring complex external positioning mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spacers have different widths in different regions (first portion with smaller width, second portion with larger width), creating local variations in the structure. This local quality differentiation allows for region-specific optimization, enabling selective repair processes where only defective regions need attention, thereby reducing overall manufacturing costs while maintaining high reliability.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12183721B2Electronic device and manufacturing method thereof

Publication Date: 2024.12.31 INNOLUX CORP

AI summary

An electronic device includes a substrate, a spacer, a first element and a second element. The spacer is disposed on the substrate and has a first portion, a second portion, a first opening, a second opening and a third opening arranged in a first direction. In a cross-section view, the second opening is located between the first opening and the third opening, the first portion is located between the first opening and the second opening, and the second portion is located between the second opening and the third opening. A width of the first portion is less than a width of the second portion in the first direction, and an area of the second opening is different from an area of the first opening. The first element is overlapped with the first opening. The second element is overlapped with the third opening.