LED Apparatus Color Filter Uniformity via CVD
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Solution Overview
Problem
Existing display devices using light emitting diodes (LEDs) face challenges in achieving high resolution due to deviations in color gamut and luminous efficiency caused by varying process conditions and environment, particularly when using red, green, and blue LEDs, and the application of fluorescent bodies and color filters can lead to non-uniform light emission and increased manufacturing time.
Innovation Solution
The method involves forming LEDs by depositing semiconductor materials on a substrate, dividing them into sub-pixels, and using color filters and fluorescent bodies to convert light, with the area of these components optimized to be smaller than the LEDs, allowing for uniform light emission and improved resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If three separate LED elements (red, green, blue) are manufactured and integrated to form one pixel, then color display capability is achieved, but manufacturing complexity increases and deviations in color gamut and luminous efficiency occur due to different process conditions
Solution Approach 1:
The patent merges the manufacturing process of multiple LED elements into a single integrated process. By forming red, green, and blue LED elements on the same substrate simultaneously using a unified manufacturing approach, the patent reduces the number of separate processes required while maintaining color display capability. This integration directly addresses the manufacturing complexity issue by consolidating multiple discrete manufacturing steps into one cohesive process.
Solution Approach 2:
The patent employs a universal manufacturing process that can produce multiple types of LED elements (red, green, blue) using the same fabrication techniques and equipment. This multi-functional approach allows a single manufacturing line to handle all color variations, eliminating the need for separate specialized processes for each LED type, thereby reducing overall manufacturing complexity while maintaining versatility in color display.
2Adaptability or versatility
If fluorescent bodies are applied to each sub-pixel by printing or dispensing to convert blue LED light to red and green, then color conversion is achieved, but the thickness of the fluorescent body becomes non-uniform causing wavelength variation and manufacturing time increases
Solution Approach 1:
The patent replaces the mechanical application methods (printing or dispensing) with a chemical vapor deposition process. This substitution eliminates the thickness non-uniformity issues associated with mechanical application, as CVD provides atomic-layer precision and uniform coverage. The chemical process naturally forms uniform fluorescent body layers without the variability introduced by manual or mechanical application techniques.
Solution Approach 2:
The patent changes the manufacturing parameters from mechanical application (printing/dispensing) to chemical deposition (CVD). This parameter change transforms the process from one that produces variable thickness to one that ensures uniform thickness control at the atomic level. The CVD process parameters (temperature, pressure, gas flow) are controlled to achieve precise and uniform fluorescent body formation across all sub-pixels.
3Adaptability or versatility
If fluorescent bodies and color filters are applied by printing or dispensing, then color conversion and filtering are achieved, but the area of these components becomes wider than the LED area making high resolution display difficult
Solution Approach 1:
The patent replaces mechanical application methods (printing/dispensing) with chemical vapor deposition for forming fluorescent bodies and color filters. CVD technology provides precise area control by depositing materials only in designated regions with sharp boundaries, preventing the components from extending beyond the LED area. This chemical approach offers better spatial control compared to mechanical methods, enabling high-resolution display by maintaining tight area constraints.
Solution Approach 2:
The patent performs preliminary patterning and definition of component areas before material deposition. By pre-defining the exact regions where fluorescent bodies and color filters will be formed, the process ensures that these components remain within the LED boundaries. This preliminary action prevents area expansion issues that would otherwise occur during material application, enabling precise area control for high-resolution displays.
4Reliability
If separate manufacturing processes are used for different LED elements, then each element can be optimized, but the number of processes increases and deviations in color gamut and luminous efficiency occur due to varying process conditions, temperature, and environment
Solution Approach 1:
The patent merges the manufacturing of different LED elements into a single integrated process that occurs under uniform process conditions. By fabricating red, green, and blue LED elements simultaneously in the same environment with the same temperature and process parameters, the patent eliminates the variations that would otherwise occur between separate processes. This unified approach ensures consistent composition and performance across all elements while maintaining the ability to optimize each element's design.
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 enhances the uniformity of light emission, improves the quality of the emitted light, and increases the resolution of display devices by ensuring consistent wavelength and reduced manufacturing time.
Implementation Method 1
forming LEDs by depositing semiconductor materials on a substrate
Implementation Method 2
using color filters and fluorescent bodies to convert light
Data Source
Figure 1~2a
Figure 2b~2c
Figure 2d~4
AI summary
A method for manufacturing a light emitting diode (LED) apparatus is provided. The method includes forming a plurality of color filters on a glass layer, forming a plurality of light leakage preventing films on the glass layer in a space between the plurality of color filters, forming a plurality of conductive materials on a surface of each of the plurality of light leakage preventing films opposite to the glass layer; and bonding a plurality of light emitting diodes with the plurality of conductive materials to correspond to the plurality of color filters, respectively.