Color Conversion Layer Stacking for Pixel Adhesion
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Solution Overview
Problem
Existing light-emitting devices face challenges in achieving high-definition image displays due to difficulties in manufacturing smaller pixels, specifically with the adhesion and processability of color conversion layers, which require precise dimensional and positional accuracy.
Innovation Solution
A light-emitting device with four or more light-emitting elements arranged on a substrate, featuring at least two types of color conversion layers continuously formed on the light exit surfaces of the elements, where one type is aligned in a column-wise direction and the other in a row-wise direction, allowing for a stacked portion where parts of these layers overlap, reducing emission intensity and enhancing adhesion and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the pixel size is reduced to achieve high-definition display, then the resolution is improved, but the adhesion and processability of color conversion layers deteriorate
Solution Approach 1:
The patent transitions from conventional separate color conversion layers for each subpixel to a shared color conversion layer structure. Multiple subpixels (red, green, blue) share a common color conversion layer, fundamentally changing the dimensional arrangement from individual layers to a shared multi-functional layer, thereby improving ease of manufacture while maintaining high definition display capability
Solution Approach 2:
The color conversion layer serves multiple functions simultaneously: it converts wavelengths for multiple different subpixels (red, green, blue) and provides adhesion support for multiple pixels. This multi-functionality resolves the contradiction by allowing a single layer structure to serve purposes that previously required multiple separate layers, improving manufacturability without sacrificing display resolution
2Measurement precision
If the color conversion layer size is reduced to match smaller pixels, then the pixel density is improved, but the dimensional and positional accuracy requirements increase
Solution Approach 1:
The patent extends the color conversion layer structure into the third dimension by creating a stacked configuration where color conversion layers are arranged in multiple layers corresponding to different subpixels. This vertical stacking approach allows each layer to be optimized for its specific subpixel while sharing common support structures, reducing the lateral precision requirements and enabling higher pixel density without proportionally increasing manufacturing difficulty
Solution Approach 2:
The patent segments the color conversion function into multiple specialized layers, with each layer dedicated to a specific subpixel type (red, green, blue). This segmentation allows each layer to be independently optimized and positioned, reducing the overall positional accuracy burden compared to a single monolithic layer serving all subpixels
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 configuration enables easy manufacturing and high-definition image displays by improving the adhesion and processability of color conversion layers, allowing for wider spacing and reduced sensitivity to dimensional errors, thus facilitating the production of smaller pixels without compromising image quality.
Implementation Method 1
color conversion layers, formed on light exit surfaces of the light-emitting elements, that convert wavelengths of light emitted from the light-emitting elements
Data Source
AI summary
A light-emitting device having four or more LEDs arranged on a substrate includes a first color conversion layer and a second color conversion layer. The first color conversion layer is continuously formed on light exit surfaces of two or more of the LEDs, and the second color conversion layer is continuously formed on light exit surfaces of two or more of the LEDs that are different from the LEDs on which the first color conversion layer is formed.