Vertical Light-Emitting Element Layout With Polymer Gap Filling
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Solution Overview
Problem
Current display devices face challenges in aligning light-emitting elements efficiently, which affects optical efficiency and manufacturing complexity.
Innovation Solution
A display device design featuring a first electrode, a bank, light-emitting elements aligned vertically, a conductive polymer layer filling gaps between elements, an insulating layer, and a second electrode, along with a reflective electrode to enhance light emission efficiency, using a method that includes growing light-emitting elements on a substrate, attaching a polymer film, forming a polymer layer, and applying light-emitting element ink via inkjet printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light-emitting elements are arranged in conventional layouts, then manufacturing is simpler, but alignment precision and optical efficiency deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-forming a conductive polymer layer on the substrate before placing light-emitting elements. This pre-prepared layer with controlled thickness and conductivity facilitates precise alignment and vertical positioning of elements during subsequent manufacturing steps, resolving the contradiction between alignment precision and structural complexity.
Solution Approach 2:
The conductive polymer layer serves as an intermediary between the substrate and light-emitting elements. It provides a controlled interface that enables precise alignment and electrical connection while simplifying the overall structure. The insulating layer similarly acts as an intermediary to manage electrical isolation and positioning, reducing manufacturing complexity while improving alignment precision.
2Illumination intensity
If conventional electrode and element arrangements are used, then device structure is simpler, but optical efficiency and emission performance worsen
Solution Approach 1:
The patent segments the device structure into distinct functional layers: conductive polymer layer, insulating layer, light-emitting elements, and electrodes. This segmentation allows optimization of each layer's properties independently - the conductive layer enhances electrical contact and light extraction, the insulating layer provides electrical isolation, and the vertical element arrangement improves optical efficiency, collectively resolving the contradiction between optical performance and structural complexity.
Solution Approach 2:
The patent transitions from conventional planar arrangements to a vertical three-dimensional configuration. Light-emitting elements are positioned vertically on the substrate, with conductive and insulating layers providing controlled spacing and electrical management. This dimensional change enhances optical efficiency by improving light extraction paths while maintaining manageable structural complexity through systematic layering.
3Manufacturing precision
If light-emitting elements are placed in direct contact with electrodes, then manufacturing is simpler, but electrical control precision and optical performance worsen
Solution Approach 1:
The conductive polymer layer acts as an intermediary between the substrate and light-emitting elements, providing controlled electrical contact and positioning. The insulating layer serves as another intermediary to ensure proper electrical isolation where needed. These intermediate layers enable precise electrical contact control without complicating manufacturing, as they can be applied using standard deposition and patterning techniques.
Data Source
AI summary
A display device may include a first electrode on a substrate, a bank covering edges of the first electrode, a plurality of light-emitting elements on the first electrode and aligned vertically with respect to the first electrode, a conductive polymer layer on the first electrode to fill gaps between the plurality of light-emitting elements, an insulating layer on the conductive polymer layer to fill the gaps between the plurality of light-emitting elements, and a second electrode on the bank, the insulating layer, and the plurality of light-emitting elements.