Micro-Scale LED Array Layout Using a Stretch Film
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Solution Overview
Problem
Conventional LED lighting devices face limitations in achieving micro-scale uniformity and durability due to wide spacing between LED chips, leading to visible LEDs and increased costs.
Innovation Solution
A method involving the formation of a separation film on a substrate, patterning, bonding a stretch film to the LEDs, stretching, and forming electrodes to achieve uniform LED arrangement and spacing, utilizing a polymeric organic material with a specific temperature difference for the stretch film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If LED chips are arranged as densely as possible using conventional methods, then spacing between LEDs is reduced, but manufacturing precision deteriorates making micro-scale devices virtually impossible to manufacture
Solution Approach 1:
The patent introduces a stretch film as an intermediary component between the substrate and the LED chips. This stretch film serves as a mediator that enables precise positioning and spacing of LEDs at micro-scale while maintaining ease of manufacture. The film is stretched to create uniform spacing between LEDs, solving the contradiction by providing a simple yet effective mechanism for achieving micro-scale precision without complex manufacturing processes.
Solution Approach 2:
The patent utilizes parameter changes by stretching the film to alter its physical dimensions and create uniform spacing. By changing the physical state of the film through stretching, the invention achieves precise LED positioning and spacing control, thereby improving manufacturing precision while keeping the manufacturing process simple and scalable to micro-scale devices.
2Illumination intensity
If additional diffusion parts are combined to address visible LED chips, then light uniformity improves, but cost increases
Solution Approach 1:
The stretch film serves multiple functions simultaneously: it provides mechanical support for the LED chips, creates uniform spacing between them, and acts as a diffusion element to achieve light uniformity. By making the stretch film multi-functional, the invention eliminates the need for separate diffusion parts, thereby improving light uniformity without increasing device complexity or cost.
3Reliability
If wide spacing is maintained between LED chips for durability, then device reliability improves, but light uniformity deteriorates making LEDs visible
Solution Approach 1:
The patent employs a stretch film, which is a flexible thin film, to create uniform spacing between LED chips. This flexible film provides mechanical support and maintains reliable spacing between LEDs while its diffusing properties ensure light uniformity. The stretch film's flexibility allows it to accommodate the LED chips while maintaining consistent spacing, thus achieving both durability and light uniformity simultaneously.
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 allows for uniform LED arrangement on a micro-scale, enhancing light uniformity and durability, while reducing costs by eliminating the need for additional diffusion parts.
Implementation Method 1
bonding the stretch film to the top surfaces of the LEDs and the spacing between the LEDs may include heat-pressing the stretch film
Implementation Method 2
stretching the stretch film, exposing the top surfaces of the LEDs
Implementation Method 3
stretching the stretch film may include shape-locking the stretch film in a stretched state
Implementation Method 4
forming the separation film may form the separation film by stacking graphene crystalline thin films in 1 to 5 layers
Implementation Method 5
removing a portion of the stretch film may include dry etching the stretch film
Data Source
AI summary
A method for manufacturing an LED lighting device includes forming a separation film on a substrate, patterning the separation film, forming LEDs on the separation film, bonding a stretch film to top surfaces of the LEDs and spacing between the LEDs, separating the separation film from the substrate, stretching the stretch film, exposing the top surfaces of the LEDs, and forming electrodes on the top surfaces of the LEDs, and a bottom surface of the separation film or bottom surfaces of the LEDs.