Ultra-Thin LED Display Layout for Easier Electrode Addressing
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Solution Overview
Problem
Existing full-color LED displays using micro-LEDs and nano-LEDs face challenges in manufacturing high-resolution displays due to high unit costs, high process defect rates, and low productivity, particularly in arranging electrodes for addressing and achieving efficient light emission with minimal surface defects.
Innovation Solution
A full-color LED display using ultra-thin LED elements with a specific geometric structure, allowing for easy ink formation and improved electron-hole recombination, is developed. The display includes a lower electrode line with sub-pixel sites, ultra-thin LED elements emitting substantially the same color, an upper electrode line, and a color conversion layer to express blue, green, and red colors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nanorod-type LED elements are used with electrodes spaced apart horizontally, then light emission is achieved, but electrode arrangement for addressing becomes difficult and manufacturing complexity increases
Solution Approach 1:
The patent inverts the conventional electrode arrangement by placing p-type and n-type electrodes vertically above and below the nanorod LED elements rather than horizontally beside them. This inversion allows electrodes to be arranged in a straightforward vertical alignment that simplifies addressing and reduces manufacturing complexity while maintaining effective current injection into the LED elements.
2Productivity
If nanorod-type LED elements are used, then light emission is achieved, but emission efficiency decreases due to small light extraction area
Solution Approach 1:
The patent transitions from horizontal light extraction to vertical light extraction by orienting the nanorod LED elements vertically with their long axes perpendicular to the substrate. This dimensional change allows light to be extracted from the top surface of the nanorods, significantly increasing the effective light extraction area and improving emission efficiency without requiring additional LED elements.
3Reliability
If nanorod-type LED elements are used, then light emission is achieved, but surface defects significantly degrade emission efficiency
Solution Approach 1:
The patent extracts the light emission function from the side surfaces of the nanorod LED elements and concentrates it in the top surface. By designing the nanorods to emit light primarily from their top surfaces rather than their side surfaces, the patent eliminates the impact of side surface defects on emission efficiency, significantly improving reliability.
4Manufacturing precision
If micro-LEDs are individually disposed on miniaturized electrodes, then high resolution display is achieved, but unit cost increases and productivity decreases
Solution Approach 1:
The patent merges multiple nanorod LED elements into arrays that can be processed and transferred as unified structures. By combining multiple LED elements into integrated nanorod arrays that maintain their individual light emission characteristics while enabling batch processing, the patent achieves high display resolution without sacrificing manufacturing productivity or increasing unit cost.
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 solution enables the manufacture of large-area, high-luminance full-color LED displays with improved efficiency and reduced surface defects, facilitating easier electrode arrangement and optimized electron-hole recombination.
Implementation Method 1
a plurality of ultra-thin LED elements, each independently emitting blue, green, or red light
Implementation Method 2
a color conversion layer patterned on the second electrode corresponding to the sub-pixel site so that each sub-pixel site becomes a sub-pixel site expressing one of blue, green, and red colors
Data Source
AI summary
The present disclosure relates to a full-color light-emitting diode (LED) display, and more particularly, to a full-color LED display using an ultra-thin LED element and a manufacturing method thereof.