Contactless μLED Micro-Display Layout for Simpler Full-Color Manufacturing
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Solution Overview
Problem
The existing manufacturing processes for full-color μLED displays are complex and costly due to the need for precise electrical contact and bonding between driving electrodes and μLED chips, as well as the use of quantum dots for color conversion, leading to longer cycles and higher production costs.
Innovation Solution
A full-color μLED micro-display device without electrical contact, where the upper and lower driving electrodes are not directly connected to the μLED grain, utilizing a control module to provide alternating driving signals and a wavelength down-conversion light-emitting layer to convert light sources into red, green, and blue colors through a color filter film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If quantum dot technology is used for color conversion in μLED display, then full-color display capability is achieved, but manufacturing complexity and production cost increase due to required precise alignment and bonding processes
Solution Approach 1:
The patent extracts and eliminates the quantum dot layer and its associated precise alignment requirements from the display structure. By using transparent electrodes that can be directly formed on the substrate without requiring precise positioning relative to the μLED chips, the complex bonding and alignment processes are removed while maintaining full-color display capability through the transparent electrode's optical properties
Solution Approach 2:
The transparent electrode serves multiple functions simultaneously: it provides electrical connection for driving the μLED chips, acts as a color conversion layer through its optical properties, and eliminates the need for separate quantum dot layers. This multi-functionality reduces manufacturing steps and complexity while achieving full-color display
2Reliability
If precise electrical contact and bonding between driving electrodes and μLED chips are implemented, then device functionality is ensured, but manufacturing cycle time increases and production cost rises
Solution Approach 1:
The patent merges the driving electrode formation process with the substrate preparation process. The transparent electrode is formed directly on the substrate in the same manufacturing sequence as other display layers, eliminating the need for separate chip bonding and electrical connection steps. This integration maintains reliable electrical contact while significantly reducing manufacturing cycle time
Solution Approach 2:
The transparent electrode is formed preliminarily on the substrate before the μLED chips are mounted. This preliminary formation of the electrical connection structure allows for simpler, faster chip placement and reduces the overall manufacturing cycle while ensuring reliable electrical contact is already in place
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 simplifies the manufacturing process, reduces production costs, and enhances the competitiveness of full-color μLED displays by eliminating the need for complex chip bonding and mass transfer processes.
Implementation Method 1
The first light source is excited into a second light source by the wavelength down-conversion light-emitting layer
Implementation Method 2
the third light source changes into red light, green light and blue light through the color filter film
Implementation Method 3
provides alternating driving signals for the upper driving electrode and the lower driving electrode, and forms a driving electric field between the upper driving electrode and the lower driving electrode
Implementation Method 4
The recombination of electrons and holes of the μLED grain is controlled and a first light source is emitted in the alternating driving electric field
Data Source
AI summary
The present invention relates to a full-color μLED micro-display device without electrical contact and a manufacturing method therefor. The device includes a lower driving electrode and a reflective layer arranged on a surface of the lower transparent substrate, an upper driving electrode and a diffusion layer arranged on a surface of the upper transparent substrate, a wavelength down-conversion light-emitting layer and a blue μLED grain arranged between the upper and lower driving electrodes, and a control module and a color filter film; the upper and lower driving electrodes are in no electrical contact with the blue μLED grain, the control module is in an electrical contact with the upper and lower driving electrodes, and the control module provides an alternating driving signal for controlling the μLED grain to excite a first light source which is converted into a second light source after passing through the wavelength down-conversion light-emitting layer, and after passing through the reflective layer and the diffusion layer, the first and second light sources achieve the full-color μLED micro-display through the color filter film. The present invention can effectively avoid the complex process for manufacturing tricolor μLED chips in the full-color μLED device, as well as the complex bonding and mass transfer processes for the light-emitting chip and the driving chip, thereby shortening the cycle for manufacturing a μLED display, and cutting down the production cost.