Through-Hole Display Structure for Vertical LED Alignment
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Solution Overview
Problem
Current display devices face challenges in aligning and fixing light emitting elements efficiently, leading to suboptimal light output efficiency and alignment accuracy, particularly due to the lack of a reliable method for vertical alignment and secure positioning of these elements within the substrate.
Innovation Solution
A display device and manufacturing method that utilize a substrate with through holes to vertically align and fix light emitting elements by exploiting pressure differences, allowing for precise positioning and secure attachment of the elements within the substrate, thereby eliminating the need for additional fixing layers and enhancing alignment accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light emitting elements are disposed on the substrate surface, then the device structure is simple, but alignment accuracy and light output efficiency are poor
Solution Approach 1:
The light emitting element is transitioned from a surface-level disposition to a vertical embedding within the substrate. The substrate includes a hole extending from the first surface to the second surface, and the light emitting element is disposed within this hole, with portions protruding from both surfaces. This dimensional transition from 2D surface mounting to 3D vertical embedding enables precise alignment while maintaining structural simplicity.
2Reliability
If additional fixing layers are used to secure light emitting elements, then positioning reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The substrate itself provides the fixing function through its hole structure. The hole extends completely through the substrate thickness, and the light emitting element is secured by the physical constraints of the hole boundaries rather than requiring separate fixing layers. This self-service approach uses the substrate's own geometry to achieve reliable positioning without additional manufacturing steps.
3Manufacturing precision
If light emitting elements are embedded in the substrate, then alignment accuracy is improved, but the substrate structure becomes more complex
Solution Approach 1:
The substrate is segmented by introducing a hole that divides the substrate into distinct regions: a first surface region, a hole region extending through the thickness, and a second surface region. This segmentation creates natural alignment boundaries that guide the light emitting element positioning while maintaining the overall substrate integrity and simplicity.
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 improves light output efficiency by ensuring direct emission of light and enhances alignment accuracy, allowing for a high-resolution display with reduced manufacturing costs through the reuse of misaligned elements.
Implementation Method 1
capable of aligning and fixing a light emitting element in a vertical direction according to a pressure difference of a substrate including a through hole
Data Source
AI summary
A display device and a manufacturing method thereof are provided. A display device according to an embodiment includes a substrate including a first emission area, and a first light emitting element disposed on the substrate and emitting light of a first color. The substrate further includes a first hole passing through the substrate in the first emission area, and at least a portion of the first light emitting element is arranged in the first hole.