Curved Metal Layer Reflects LED Light
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Solution Overview
Problem
Micro LED displays face challenges in enhancing the directivity of light emitted from LED chips, as the light is emitted with weak directivity and spreads in various directions, leading to inefficient light utilization.
Innovation Solution
The LED module incorporates a first metal layer with a curved portion and a notch portion that forms a contour away from the base surface, acting as a reflective surface to enhance light directivity, where the metal layer is formed using high reflectance materials like aluminum, copper, or silver, and the curved portion is created through heat treatment to surround the LED chip, ensuring the light is reflected and focused in a specific direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a flat metal layer is used as electrode, then the manufacturing process is simple, but the light directivity is poor and light utilization is inefficient
Solution Approach 1:
The metal layer is designed with a curved surface instead of a flat surface. The curvature causes incident light from the LED chip to reflect at various angles, directing light forward and improving light directivity and utilization efficiency.
Solution Approach 2:
The metal layer serves dual functions: it acts as both an electrical electrode and an optical reflective surface. This multi-functionality improves light directivity without requiring additional components, thus avoiding increased device complexity.
2Illumination intensity
If separate electrode and reflective surface structures are used, then light directivity is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The metal layer is designed to perform both electrical and optical functions simultaneously. By forming the metal layer with appropriate curvature during the electrode formation process, the same structure serves as both electrode and reflective surface, eliminating the need for separate components.
Solution Approach 2:
The electrode function and reflective surface function are merged into a single metal layer structure. This integration simplifies the overall device structure and reduces manufacturing complexity while achieving improved light directivity.
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 effectively improves the directivity of light emitted from the LED chip, enhancing light utilization and increasing the productivity of the LED module by using the metal layer as both an electrode and a light reflecting surface, without requiring complex processes.
Implementation Method 1
performing heat treatment on the first metal layer. The heat treatment forms a curved portion in the first metal layer
Implementation Method 2
The heat treatment forms a curved portion in the first metal layer, and the curved portion forms a shape in which the first end portion is away from the base surface
Implementation Method 3
acting as a reflective surface to enhance light directivity, where the metal layer is formed using high reflectance materials like aluminum, copper, or silver, and the curved portion is created through heat treatment to surround the LED chip, ensuring the light is reflected and focused in a specific direction
Data Source
AI summary
An LED module includes a first metal layer disposed on a base surface and an LED chip disposed on the first metal layer. The first metal layer includes a first end portion forming a contour away from the base surface, and a curved portion between a region overlapping the LED chip and the first end portion.