Integrated microled display with power conversion structures

Abstract

The present disclosure relates to integration of power conversion layers or structure into the MicroLED enabled display. In particular, the invention discloses three principal integration methods, solar cell laminated to the back of the display wherein a separate solar cell layer is laminated to the display's backplane surface, aligned with transparent pixel areas to allow light harvesting, shared substrate for display and solar cell wherein display and solar cell layers are fabricated on the same substrate, either on the same side or on opposite sides, reducing thickness and simplifying manufacturing, and solar sell on top of the display wherein transparent photovoltaic materials are deposited on the front of the display, acting as a protective layer while generating power.

Description

Atorney Docket 075913-000160WGPTINTEGRATED MICROLED DISPLAY WITH POWER CONVERSION STRUCTURESBackground and Field of the invention

[0001] The present invention relates to display technologies, and more particularly to transparent MicroLED displays integrated with power conversion structures, such as solar cells, to enhance functionality and energy efficiency.

[0002] MicroLED technology offers high brightness, transparency, and efficiency, making it ideal for applications requiring advanced display performance. Integrating power generation capabilities, such as solar cells, into these displays can provide additional functionality, such as self-sustaining energy generation, without compromising display performance. This invention explores various configurations and methods for achieving such integration.Summary

[0003] The present invention relates to a method to integrate a solar cell structure into MicroLED display, the method comprising, having the MicroLED display with a transparent area for light to pass through, and laminate the solar cell structure to a back side of the MicroLED display where the backside of the MicroLED display is a backplane surface and wherein further the transparent area is located per each pixel and the MicroLED display has a substrate and active layers which form pixels and generate images.Brief Description of the Drawings

[0004] The foregoing and other advantages of the disclosure will become apparent upon reading the following detailed description and upon reference to the drawings.

[0005] Figure 1 illustrates an integrated structure in which a display is laminated to a solar cell.

[0006] Figure 2 illustrates a display structure with solar cell layer on the display substrate.

[0007] While the present disclosure is susceptible to various modifications and alternative forms, specific embodiments or implementations have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of an invention as defined by the appended claims.14900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPTDetailed Description

[0008] The present invention provides methods and systems for integrating a solar cell structure into a MicroLED display. The MicroLED display includes transparent areas per pixel to allow incident light to pass through to a laminated or integrated solar cell structure located at the backplane of the display.

[0009] The present invention provides an innovative approach to integrating power generation capabilities with transparent MicroLED displays, enabling energy-efficient, multifunctional systems suitable for a variety of applications. These embodiments reduce system complexity, enhance durability, and maintain superior display performance.

[0010] The invention covers the following three principal integration methods:!) Solar Cell Laminated to the Back of the Display - A separate solar cell layer is laminated to the display's backplane surface, ii)aligned with transparent pixel areas to allow light harvesting, Shared Substrate for Display and Solar Cell - Display and solar cell layers are fabricated on the same substrate, either on the same side or on opposite sides, reducing thickness and simplifying manufacturing and iii) Solar Cell on Top of the Display - Transparent photovoltaic materials are deposited on the front of the display, acting as a protective layer while generating power. These configurations improve energy efficiency, reduce manufacturing complexity, and maintain high-quality display performance.

[0011] The present invention provides an integrated MicroLED transparent display system comprising various configurations for combining display and power generation structures. These embodiments improve energy efficiency, reduce system complexity, and maintain high- quality display performance. Key embodiments are described below.Solar Cell Laminated to the Back of the Display

[0012] In one embodiment, a solar cell structure is laminated to the back of the transparent MicroLED display. Light passes through the openings in the display pixels and the display substrate before reaching the solar cell structure, where it is converted into electricity. In this embodiment, the MicroLED display is fabricated first (complete or partially completed), and then a solar cell module is laminated onto its backplane surface (the non-emitting side). The transparent areas between pixels allow light to pass through to the solar cell for energy harvesting.

[0013] The key is to preserve: a) Optical transparency in non-emissive regions, b) Display performance (color, contrast, brightness), and c) Mechanical reliability after lamination.24900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT

[0014] The substrate of either the display or the solar cell can be thinned to reduce the overall stack thickness. Transparent conductive materials, such as indium tin oxide (ITO) or graphene, may be utilized to enhance optical transparency and electrical conductivity.

[0015] Figure 1 illustrates an integrated structure in which a display is laminated to a solar cell (102). The display incorporates transparent areas (108) that allow light to pass through to the solar cell for power generation. The structure provides a dual -functional system where the display serves its primary role of image rendering while also enabling light harvesting via the solar cell.

[0016] Figure 1 shows a display structure laminated to a solar cell 104. Here the display has transparent area 108 where the light can pass through. A solar cell structure 102 is laminated to the back side of the display where the backside of the display is the backplane surface where it is not used for light and image generation. The display is an emissive display. The emissive display can be a MicroLED display where it allows for larger transparent area 108. The transparent area 108 is located per each pixel. The display has a substrate 104 and active layers 106 which form pixels and generate images. The substrate 104 can be thinned. In another case, substrate 104 can be a polymer that is delaminated from a career substrate and laminated to the substrate. The solar cell has substrate 102 and can have different active layers 110. The substrate 102 can be thinned. The substrate 102 can be a polymer layer that is delaminated from a carrier substrate after the solar cell is laminated to the display substrate 104. An antireflection coating is done on the back surface of the display or on surface of the solar cell before laminating the solar cell to the display.

[0017] The area outside the transparent area 108 can be covered by a black matrix to reduce the display reflection and improve the display performance.

[0018] There can be extra process steps on the display after lamination to the solar cell. The process can include micro device integration, interconnect formation, packaging, and so on. In one embodiment, the display is a collection of tiles laminated to a substrate with solar cells.

[0019] The Display Structure is detailed as follows.

[0020] The display is an emissive display, such as a MicroLED display, chosen for its capability to support a large transparent area (108) within each pixel. This structure maximizes transparency and facilitates efficient light transmission to the underlying solar cell. The display comprises of the following layers, i) Substrate (104) and ii) Active Layers (106).

[0021] The substrate (104) can be thinned to reduce the overall thickness of the system, thereby enhancing flexibility and making it suitable for compact and lightweight devices. In an34900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT alternative implementation, the substrate (104) can be a polymer layer delaminated from a carrier substrate and subsequently laminated onto the display.

[0022] The Active Layers (106) include the pixels that generate light and form the displayed image transparent areas (108) are positioned within each pixel, enabling light to travel through the display and reach the solar cell beneath.

[0023] The Solar Cell Structure is detailed as follows: The solar cell is laminated to the back surface of the display. The back surface refers to the backplane surface of the display, which is not used for light emission or image generation, ensuring that no functional areas of the display are obstructed. The solar cell comprises: Substrate (102) which can also be thinned to minimize the stacked thickness of the integrated structure. Alternatively, the substrate (102) can be a polymer layer delaminated from a carrier substrate after the solar cell is laminated to the display substrate (104).

[0024] The solar cell further comprises Active layers (110). These layers are responsible for converting light into electrical energy. Different types of solar cells can be used, including silicon-based, perovskite, or organic photovoltaic materials, depending on the application requirements and desired transparency.

[0025] The Surface Treatments may comprise an Antireflection Coating. An antireflection coating can be applied to the back surface of the display to enhance light transmission to the solar cell and the surface of the solar cell prior to its lamination onto the display. This reduces reflection losses, improves optical efficiency, and enhances both display quality and solar cell performance.

[0026] The Black Matrix comprises of areas of the display outside the transparent areas (108) can be covered with a black matrix. This serves to: i) Reduce reflections from the display surface, ii) Improve contrast and overall display performance and iii) Absorb stray light, thereby minimizing light leakage that could reduce the effectiveness of the solar cell.

[0027] Post-Lamination Processing comprises after the solar cell is laminated to the display, additional processing steps can be performed to enhance functionality and integrate the system.

[0028] One step would be for Microdevice Integration wherein microLEDs or other microdevices can be integrated into the display for additional features such as sensi’ng or adaptive functionality.

[0029] Another step would be for an Interconnect Formation; wherein electrical interconnects can be created between the display and solar cell to support power-sharing or monitoring functionalities.44900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT

[0030] Another step would be of Packaging wherein encapsulation processes can protect the integrated structure from environmental factors like moisture, dust, or physical damage.

[0031] Tiled Display Integration comprises wherein inn one embodiment, the display is constructed as a collection of tiles that are laminated onto a larger substrate featuring solar cells. This modular approach provides: i) Scalability for larger displays or non-standard form factors and ii) Enhanced manufacturability by enabling independent fabrication of display tiles and solar cells before integration.

[0032] The following are advantages of the embodiment: Energy Efficiency: Combines display functionality with solar energy harvesting for power generation, Compactness wherein Thinning of substrates and use of polymer materials minimize system thickness and weight, Improved Display Performance wherein Black matrix and antireflection coatings enhance contrast, reduce reflections, and maintain visual clarity and Scalability wherein Modular tiled displays allow for flexible design and adaptation to various applications.

[0033] General Structure for Solar Cell Laminated to the Back of the Display: In a first embodiment, a solar cell structure (102) is laminated to the back surface of a transparent MicroLED display. The MicroLED display comprises a substrate (104) supporting active emissive layers (106) forming pixels, wherein transparent areas (108) are provided within each pixel or pixel gap to allow ambient light to pass through the display and reach the solar cell structure (102). The backside of the display is a backplane surface, which does not emit light or form part of the primary image generation. Light transmitted through the transparent areas is converted into electrical power by the solar cell active layers (110).

[0034] Overall, there may be Potential Exemplary Material Variations. Display Substrate (104); Rigid glass, ultra-thin glass (<100 pm), flexible polymers including polyimide (PI), cyclic olefin polymer (COP), polyethylene terephthalate (PET), or combinations thereof. May be thinned or delaminated from a carrier substrate to reduce total stack thickness. Transparent Conductors; Indium tin oxide (ITO), indium zinc oxide (IZO), silver nanowires, carbon nanotubes, or graphene. Solar Cell Substrate (102); Glass, flexible polymer films, or metal foils (e.g., stainless steel, titanium). May be thinned to <150 pm for flexibility. Solar Cell Active Layers (110); Crystalline silicon (mono- or poly-crystalline), thin-film silicon, copper indium gallium selenide (CIGS), cadmium telluride (CdTe), perovskite photovoltaic layers, organic photovoltaics (OPV), or dye-sensitized solar cells (DSSC). Transparent or semi-transparent PV materials may be used to maintain high display transparency.

[0035] For Surface Treatments prior to lamination, one or both of the display and solar cell surfaces may be coated with: i)Antireflection (AR) coatings to reduce Fresnel reflection and54900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT improve optical coupling, ii) Index-matching coatings to minimize refractive index discontinuities, and iii) Passivation layers (e.g., silicon nitride, aluminum oxide) to prevent environmental degradation.

[0036] The following are some exemplary fabrication methods for the aforementioned embodiment.

[0037] Fabrication Method 1 - Optically Clear Adhesive (OCA) Lamination: In one method, the solar cell structure is laminated to the display backplane using an optically clear adhesive layer. Here: i) The display and solar cell are separately fabricated, ii) The solar cell is thinned and, if flexible, deposited on a polymer substrate, iii) A uniform OCA layer (25-150 pm) is applied to either the display or the solar cell, iv) The components are aligned such that transparent areas (108) correspond to active PV regions, v) Lamination is performed under vacuum or nitrogen to avoid air entrapment, and vi) Adhesive is cured using UV or thermal processes depending on adhesive chemistry. This method provides scalable, low-cost manufacturing and high optical clarity when refractive indices are matched.

[0038] Fabrication Method 2 - Direct Wafer-to-Substrate Hybrid Bonding: In another related method, no adhesive is used. Here; a) Both the display backplane and solar cell surfaces are planarized via chemical-mechanical polishing (CMP) to achieve a surface roughness of <1 nm RMS, b) Surfaces are activated using plasma treatment (O2, N2, or Ar plasma), c) The surfaces are brought into contact in a cleanroom environment, bonding via direct molecular forces, and d) A low-temperature anneal (100-200°C) strengthens the bond. This approach maximizes optical transparency and long-term mechanical stability.

[0039] Fabrication Method 3 - Glass or Polymer Interposer Lamination: In a further method, a transparent interposer layer is positioned between the display and the solar cell. Her; a) The interposer may be glass or high-optical-clarity polymer, b) Micro-vias or through-holes may be included for electrical interconnection, c) The solar cell is bonded to one side of the interposer; the display is bonded to the opposite side, and d) Optical-grade epoxy or UV- curable adhesive is used for lamination. The interposer can integrate additional optical filters, diffusers, or heat-spreading layers.

[0040] Fabrication Method 4 - Roll-to-Roll Lamination for Flexible Systems; For flexible devices; a) MicroLEDs are fabricated on a flexible polymer substrate (PI, PET), b) Flexible solar cells (e.g., OPV, perovskite) are fabricated on a polymer backplane, c) Both webs are aligned and laminated in a continuous roll-to-roll process, and d) Lamination uses either OCA or thermoplastic adhesives compatible with high-throughput production. This method is suited for large-area, lightweight smart windows and wearable displays.64900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT

[0041] Fabrication Method 5 - Adhesive-Free Vacuum Press Lamination. In another variant; a) Display and solar cell surfaces are AR-coated and polished, b) Lamination is performed in a vacuum chamber under controlled heat and pressure without adhesive, c) Bonding is achieved via Van der Waals forces or micro- structured interlocking surfaces, and d) Edge sealing using UV epoxy, glass frit, or metal frames provides environmental protection. This method offers maximum optical clarity and avoids adhesive-related aging issues.

[0042] Post Lamination Processing may comprise of the following. After lamination by any method, the assembly may undergo; a) Microdevice integration for additional sensing or control functions, b) Electrical interconnect formation to share or manage power between the display and the solar cell, and c) Encapsulation using glass, polymer films, or atomic layer deposition (ALD) coatings for environmental durability.Shared Substrate for Display and Solar Cell

[0043] In another related embodiment, the display and solar cell share a common substrate. The solar cell structure is fabricated on the substrate first, followed by the transparent display layers on top of it. This embodiment eliminates the need for separate substrates, thereby reducing material usage, manufacturing complexity, and display thickness. Advanced materials, such as flexible polymers, ultrathin glass, or transparent photovoltaic materials (e.g., perovskite solar cells), can be employed to maintain both transparency and functionality.

[0044] Figure 2 illustrates a structure in which the display is formed on a substrate that also incorporates solar cell layers. This integration enables a dual-functionality system where the display provides visual output, and the solar cells generate electrical power from incident light. The structure allows for various configurations of the display and solar cell layers on the substrate.

[0045] Figure 2 shows a structure where the display is formed on substrate with solar cell layers. Here, solar layers are formed or transferred onto a substrate surface. In one related embodiment, display structures and layers including pixel circuits, electrodes, and emissive devices (e.g. MicroLED) are formed on the display substrate. There can be extra layers between solar cells and display layers. These layers can be planarization, passivation, antireflection layers, and so on. In one related embodiment, the display and solar layers are formed on the same surface of substrate 104. In another related embodiment, the solar cell and display layers are formed on different sides of the substrate. In another related embodiment, the solar cell is formed after the display layers. Here, the solar cell is either transferred into the display or it is deposited using conventional processes such as PECVD, sputtering, or coating methods. The area in the74900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT solar cell that is associated with the lighting area in the display can be patterned and removed. There can be a passivation layer on the display prior to the formation of the solar cell.

[0046] The Solar Cell Formation on the Substrate is as follows.

[0047] Initial Solar Cell Layers: Solar layers are either formed or transferred onto the substrate surface. These solar layers may include materials such as silicon, perovskite, or organic photovoltaic (OPV) layers.

[0048] Methods of Formation: Here; Deposition techniques such as PECVD (Plasma Enhanced Chemical Vapor Deposition), sputtering, spin coating, or different printing techniques can be used to create the solar cell layers directly on the substrate. Alternatively, solar cell layers may be fabricated separately and transferred onto the substrate via methods such as lamination or transfer printing.

[0049] For Display Layer Formation there are Display Layers on Substrate and Layer configurations.

[0050] For Display Layers on Substrate display structures and layers are formed on the same substrate, including a) Pixel Circuits: To drive individual pixels, b) Electrodes: Transparent or reflective electrodes for efficient light emission and current flow, and c) Emissive Devices: Such as MicroLEDs or other emissive materials for image generation.

[0051] For Layer Configurations, in one embodiment, the display layers and the solar cell layers are formed on the same side of the substrate. In another embodiment, they are formed on opposite sides of the substrate, optimizing the functionality of each.

[0052] For Intermediate Layers the following processes are considered; a) Planarization Layers: Added to create a smooth surface for subsequent layer deposition, ensuring uniformity in the display and solar cell integration, b) Passivation Layers: Protect the underlying layers from environmental factors such as moisture or oxygen and isolate electrical components to prevent short circuits, c) Antireflection Layers: Minimize reflection losses, ensuring maximum light transmission to both the display and the solar cell. These layers can be applied between the solar cell and display layers or on their outer surfaces, and d) Patterning and Removal: Areas of the solar cell associated with the display’s lighting area may be patterned and selectively removed to ensure that the display’s brightness and transparency are not compromised.

[0053] For Configuration Variations the following aspects are important:

[0054] Display and Solar Cell are on the Same Surface: Here the display layers (e.g., pixel circuits, electrodes, MicroLEDs) and solar cell layers are formed on the same side of the84900-6333-2450.1075913-000160WQPTAttorney Docket 075913-000160WOPT substrate. There are advantages such as Simplifying the fabrication process and minimizing substrate complexity.

[0055] Display and Solar Cell being on Opposite Surfaces: Here the display layers are formed on one side of the substrate, and the solar cell layers are formed on the opposite side. The advantages are that this ensures that solar cell functionality does not interfere with the display operation and protects the solar cells from environmental exposure by positioning them on the inner side of the system.

[0056] When Solar Cell Formed After Display Layers. In this embodiment, the display layers are fabricated first, followed by the formation or transfer of the solar cell layers.

[0057] Following are the Methods of Solar Cell Integration: a) Deposition: Using conventional techniques such as PECVD, sputtering, or coating methods, and b) Transfer: Prefabricated solar cells can be laminated or bonded onto the display surface.

[0058] For Passivation Layers, a passivation layer can be applied to the display before the formation of the solar cell to protect the display layers and ensure compatibility with the deposition or transfer process.

[0059] The following are the advantages of the embodiment: a) Compact Design: Integrating both display and solar cell layers on a single substrate reduces the overall system thickness and weight, b) Enhanced Transparency: Selective removal of the solar cell material in areas corresponding to display lighting ensures optimal transparency and brightness, c) Improved Durability: Passivation layers and careful layer stacking enhance the environmental robustness of the integrated system and d) Flexible Fabrication: Various methods for solar cell and display integration allow for adaptation to different manufacturing processes and material systems.

[0060] General Structure for Shared Substrate for Display and Solar Cell.

[0061] In a second embodiment, the display layers and solar cell layers share a common substrate (104), thereby eliminating the need for separate substrate components and reducing the total system thickness. The shared substrate supports both the photovoltaic structure and the display circuitry, with transparent or patterned areas enabling light passage to the solar cell. This integration can be implemented in multiple configurations, including same-side fabrication, opposite-side fabrication, and sequential formation with intermediate processing layers.

[0062] Overall, there may be Potential Exemplary Material Variations. For Material Variations - Shared Substrate (104) there may be a) Rigid Substrates: Alkali-free display-grade glass, ultra-thin glass (<100 pm), quartz, b) Flexible Substrates: Polyimide (PI), polyethylene naphthalate (PEN), cyclic olefin polymer (COP), transparent polyethylene terephthalate (PET),94900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT and c) Specialty Substrates: Transparent ceramic composites, sapphire, or engineered multilayer laminates combining glass and polymer.

[0063] Solar Cell Active Layer Materials can be the following, a) Crystalline Silicon: Monocrystalline or polycrystalline thin slices (<50 pm), b) Thin-Film Photovoltaics: Amorphous silicon, cadmium telluride (CdTe), copper indium gallium selenide (CIGS), c) Emerging PV Materials: Perovskite photovoltaics (single-junction or tandem), organic photovoltaics (OPV), dye-sensitized solar cells (DSSC), and d) Transparent PV: High- transmittance perovskite or OPV tuned to absorb non-visible wavelengths.

[0064] The display layers may include:(a) Thin-film transistor (TFT) backplane (oxide TFT, LTPS, LTPO).(b) Pixel driver circuits.(c) Transparent or reflective electrodes (ITO, IZO, silver nanowires, graphene).(d) MicroLED emissive layers with defined transparent regions.(e) Passivation and encapsulation layers.(f) Intermediate Layers Between Display and Solar Cell(g) Planarization Layers: Polyimide, benzocyclobutene (BCB), spin-on glass (SOG), and(h) Passivation Layers: Silicon nitride (SiNx), silicon oxide (SiOx), aluminum oxide (AI2O3).(i) Optical Enhancement Layers: Anti-reflection (AR) coatings, index-matching layers, optical bandpass or notch filters to optimize PV response without altering display color performance.

[0065] Following are the fabrication methods for Shared Substrate for Display and Solar Cell.

[0066] Fabrication Method 1 - Same-Side Sequential Deposition: Here the method comprises a process flow; a) Deposit or transfer solar cell layers (e.g., perovskite or CIGS) onto the substrate, b) Apply an optically transparent encapsulation layer over the PV structure, c) Form planarization and isolation layers, d) Fabricate the display layers (TFT backplane, pixel electrodes, MicroLED devices) on top of the planarized surface, and e) Pattern transparent regions above PV cells for light coupling.

[0067] The advantages for this fabrication method are; Simplifying manufacturing to a single substrate, reduces system thickness and part count and lower alignment complexity.

[0068] Fabrication Method 2 - Opposite-Side Integration: Here the method comprises a process flow, a) Form the solar cell structure on one side of the substrate., b) Flip substrate and fabricate display layers on the opposite side, c) Use thin or transparent substrate material to104900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT allow light to reach solar cells from the front side, anddO Apply AR coating to the rear of the display for improved light transmission.

[0069] The advantages for this fabrication method are reducing thermal cross-interference between display and solar fabrication steps, and Solar cells being protected between display and external housing.

[0070] Fabrication Method 3 - Solar Cell Fabricated First, Display Formed Afterwards; Here the process flow is; a) Deposit or transfer solar cell onto substrate using PECVD, sputtering, evaporation, spin coating, or printing, b) Add planarization and passivation layers, c) Fabricate display circuitry and MicroLED layers on top, and dO Form openings in non-emitting regions for light passage to PV cells.

[0071] The advantages for this fabrication method are optimizing PV fabrication conditions before sensitive display materials are deposited and it allows high-efficiency PV processes that require higher temperatures.

[0072] Fabrication Method 4 - Display Fabricated First, Solar Cell Added Afterwards. Here the process flow is, a) Fabricate complete display layers on the substrate, b) Deposit or transfer solar cell layers directly onto exposed transparent areas of the display, cO Apply selective removal or patterning of PV layers in emission zones to maintain image quality, and d) Encapsulate with transparent protective layer.

[0073] The advantages for this fabrication method are minimizing PV exposure to contamination during display fabrication and it allows later addition of PV functionality to an existing display product line.

[0074] Fabrication Method 5 - Interleaved Photovoltaic & Display Layering: Here the process flow is, a) Pattern the substrate into alternating PV-active and display-active regions, b) Fabricate PV and display devices in separate patterned zones, c) Use transparent planarization layers to create a uniform surface, and d) Electrically integrate PV and display circuits for power sharing.

[0075] The advantages for this fabrication method are that it allows different optimization for PV and display zones and can be used for partially transparent displays or patterned smart glass.

[0076] Optical Management Enhancements; For all methods above, optical coupling between front-incident light and the solar cell may be enhanced via; a) Multi-layer AR stacks tuned for both display emission and PV absorption bands, b) Transparent scattering layers to redirect oblique light into PV regions, and c) Selective wavelength filters to pass unused portions of the visible or near-IR spectrum to PV cells.114900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT

[0077] In Post-Fabrication Processing after integration, optional processes may include, a) Encapsulation: Glass capping, ALD coatings, moisture barrier films, b) Edge Sealing: UV- cured epoxies, metal perimeter seals, b) Thermal Management: Transparent graphene or diamond-like carbon heat spreaders, and d) Electrical Integration: Shared bus lines, embedded power management ICs.

[0078] The advantages of Embodiment 2 are such that this architecture offers reduced thickness, lower weight, and manufacturing efficiency by eliminating separate substrates. It also improves structural integrity, enables high transparency by patterning PV layers in nonemitting zones, and supports both rigid and flexible implementations. The shared substrate approach facilitates both mass production for consumer electronics and large-area integration for automotive, architectural, and industrial displays.Solar Cell on Top of the Display

[0079] In yet another embodiment, the display is fabricated first, and the solar cell structure is formed on top of it. The solar cell can utilize transparent photovoltaic materials to allow light to pass through to the display while simultaneously generating electricity. The solar cell can have an opening for microLEDs to allow the lights pass through. A planarization layer can be used prior to improving the surface flatness. This configuration protects the display from environmental factors, with the solar cell acting as a shield.

[0080] In this configuration, the display image and the solar can be in the same plane. Antireflection coatings can be added between the solar cell and the display layers to improve light transmission and reduce reflections. Encapsulation methods can be employed to enhance durability and environmental resistance. Ideal for outdoor applications, such as automotive heads-up displays (HUDs), outdoor signage, and high-ambient-light environments.

[0081] Fabrication Methods for solar Cell on Top of the Display are the following.

[0082] Direct Deposition of Thin-Film Solar Cells comprising depositing solar absorber and junction layers directly on top of the transparent display cover layer (e.g., glass, polymer). This method can include a) Sputtering / evaporation: For TCO (transparent conductive oxides) and thin-film semiconductors, b) CVD / ALD: For conformal coatings (useful if covering curved displays), and c) Solution-based methods: Spin-coating or slot-die coating for perovskites or organic photovoltaics (OPVs).

[0083] Lamination of Prefabricated Solar Films comprising fabricating solar cells separately (roll-to-roll or wafer-based) and laminate onto the display surface. This method can include124900-6333-2450.1075913-000160WQPTAttorney Docket 075913-000160WQPT adhesive bonding (optically clear adhesive with refractive index matching). This method allows independent optimization of display and PV processes.

[0084] Transparent Conductive Interposers comprising inserting a transparent solar cell layer between the cover glass and display optical stack using a conductive interposer (graphene, Ag nanowires, ITO). This method can include sheet transfer or CVD growth of conductive layers. It may also maintain optical transparency while harvesting ambient light.

[0085] Exemplary material options for these aforementioned methods can be as follows: a) Active Layer Materials which further comprise l)Perovskite Photovoltaics: High efficiency (>20%), tunable bandgap (400-800 nm), compatible with low-temperature processing with potential for semi-transparent designs, 2) Organic Photovoltaics (OP Vs) that are highly transparent, flexible, lightweight, with moderate efficiency (10-15%), but excellent aesthetic integration, 3) Amorphous Silicon (a-Si:H); with established technology ad are stable and scalable, with efficiency ~6-10%, but work well for indoor light harvesting, 4) CIGS (Copper Indium Gallium Selenide) which is flexible thin-film with efficiency up to 20%, with higher material cost, but strong candidate for curved displays, nd 5) III-V Solar Cells (GaAs, InP) with ultra-high efficiency (>30%), thin epitaxial lift-off possible. These are costly, but suitable for premium applications.

[0086] Transparent Electrodes that may include, Indium Tin Oxide (ITO), Graphene sheets (flexible, mechanically robust), Silver nanowire meshes (transparent, conductive) and Ultrathin metal films (Ag, Au with dielectric capping).

[0087] Encapsulation Materials may include UV-stable polymers (e.g., fluoropolymers) and Glass or hybrid barrier films to protect solar layers from moisture / oxygen

[0088] In another related embodiment, patterned Solar Cell with Micro-Openings are used. Instead of requiring a fully transparent solar cell, the photovoltaic layer is selectively patterned to form openings aligned with the light-emitting areas of the microLED display. This ensures that the display’s emitted light exits without significant absorption while the surrounding regions harvest ambient light.

[0089] The solar cell can be made from high-efficiency opaque materials (e.g., crystalline Si, perovskite, or III-V semiconductors) rather than being constrained to semi-transparent low- efficiency designs.

[0090] Fabrication Approaches for Patterned PV Integration are the following: a) Photolithographic Patterning, b) Laser Scribing, c) Inkjet Printing / Selective Deposition and d) Micro-Patterned Transfer of Thin Solar Films.134900-6333-2450.1075913-000160WGPTAttorney Docket 075913-000160WQPT

[0091] For Photolithographic Patterning, use photolithography to define micro- or nano-scale openings in the solar absorber and electrode layers, alignment with the microLED pixel layout ensures minimal shading, and suitable for high-resolution displays.

[0092] For Laser Scribing, direct laser ablation removes solar cell material at defined regions corresponding to display pixels and this is cost-effective for large-area and medium-resolution panels (e.g., automotive or signage).

[0093] For Inkjet Printing / Selective Deposition, we have Inkjet-print perovskite or OPV absorbers only in the regions between display pixels. There is no additional etching required, and this is compatible with roll-to-roll processes for flexible displays.

[0094] For Micro-Patterned Transfer of Thin Solar Films, there is transfer of prefabricated solar films (e.g., III-V layers) onto the display surface with micro-patterned adhesive bonding, leaving open regions over the emitters. This ensures high efficiency while maintaining controlled pixel apertures.144900-6333-2450.1075913-000160WGPT

Claims

Atorney Docket 075913-000160WGPTCLAIMS1. A method to integrate a solar cell structure into MicroLED display, the method comprising: having the MicroLED display with a transparent area for light to pass through; and laminate the solar cell structure to a back side of the MicroLED display where the backside of the MicroLED display is a backplane surface and wherein further the transparent area is located per each pixel and the MicroLED display has a substrate and active layers which form pixels and generate images.

2. The method of claim 1, wherein the backplane surface is not used for light and image generation.

3. The method of claim 1, wherein the MicroLED display is an emissive display enabling a larger transparent area.

4. The method of claim 1, wherein the substrate is thinned to reduce an overall thickness of a system, thereby enhancing flexibility and making a compact and lightweight device.

5. The method of claim 1, wherein the substrate is a polymer that is delaminated from a career substrate and laminated to the substrate.

6. The method of claim 1, wherein an antireflection coating is done on the back surface of the MicroLED display or on a surface of the solar cell before laminating the solar cell to the display.7 .The method of claim 1, wherein an area outside the transparent area is covered by a black matrix to reduce a display reflection and improve a display performance.

8. The method of claim 1, wherein the light passes through openings in display pixels and a display substrate before reaching the solar cell structure, where it is converted into electricity.

9. The method of claim 1, wherein the MicroLED display is fabricated first and then a154900-6333-2450.1075913-000160WQPTAtorney Docket 075913-000160WGPT solar cell module is laminated onto its backplane surface.

10. The method of claim 8, wherein the transparent areas between pixels allow light to pass through to the solar cell for energy harvesting.

11. The method of claim 9, wherein an antireflection coating is done on the back surface of the display or on surface of the solar cell before laminating the solar cell to the display12. The method of claim 1, wherein the transparent area is covered by a black matrix to reduce a display reflection, improve contrast and a display performance.13 .The method of claim 1, wherein the display is a collection of tiles laminated to a substrate with solar cells.

14. The method of claim 1, wherein the transparent area is covered by a black matrix to absorb stray light, thereby minimizing light leakage that reduces the effectiveness of the solar cell.

15. The method of claim 9, wherein MicroLEDs or other microdevices are integrated into the display for additional features such as sensing or an adaptive functionality.

16. The method of claim 9, wherein electrical interconnects are created between the display and solar cell to support power-sharing or monitoring functionalities.

17. The method of claim 9, wherein encapsulation processes are used to protect the integrated structure from environmental factors like moisture, dust, or physical damage.164900-6333-2450.1075913-000160WQPT

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