LED Wavelength Conversion Film for Uniform Full-Color Displays
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Solution Overview
Problem
Light-emitting diode displays face issues such as uneven illumination, electrical controlling difficulties, and high manufacturing costs due to the use of red, green, and blue light-emitting diode chips.
Innovation Solution
The method involves forming a wavelength conversion film directly on the top and side surfaces of LED chips to create chip-scale packaged white light-emitting units, which are then transferred onto a substrate with a color filter layer to produce uniform illumination and reduce material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If red, green, and blue light-emitting diode chips are used to form pixels in a light-emitting diode display, then full-color display capability is achieved, but uneven illumination and electrical controlling difficulties occur
Solution Approach 1:
The invention segments the display into individual light-emitting units, each containing a single LED chip with wavelength conversion film, allowing independent control and uniform illumination across the display area
Solution Approach 2:
The wavelength conversion film acts as an intermediary that converts blue or ultraviolet light from the LED chip into red and green wavelengths, enabling full-color display through a single chip type while maintaining uniform illumination and simplified electrical control
2Productivity
If traditional LED chip arrangements are used, then display functionality is achieved, but device size cannot be reduced and manufacturing cost is high
Solution Approach 1:
The wavelength conversion film is integrated directly onto the LED chip surface, nesting the conversion function within the chip structure itself, which reduces overall device size while maintaining full-color display functionality
Solution Approach 2:
The invention merges the wavelength conversion function with the LED chip structure by forming the conversion film directly on the chip, eliminating separate conversion components and reducing device volume
3Productivity
If traditional LED chip arrangements are used, then display functionality is achieved, but manufacturing cost is high due to material usage
Solution Approach 1:
The invention extracts unnecessary materials and components from traditional multi-chip arrangements, using only blue or ultraviolet LED chips with wavelength conversion film, thereby reducing material consumption and manufacturing cost while maintaining display functionality
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 illumination uniformity, simplifies electrical control, and reduces production costs by minimizing the overall size and material usage of the display device.
Implementation Method 1
The wavelength conversion film directly covers the top surface and the side surfaces of the light-emitting diode chip... each of the white light-emitting units comprises a light-emitting diode chip and a wavelength conversion film
Implementation Method 2
The wavelength conversion film, which includes a plurality of first quantum dots and a plurality of second quantum dots, and a wavelength range of light excited from the first quantum dots are different from a wavelength range of light excited from the second quantum dots
Data Source
AI summary
A method of manufacturing a light-emitting unit includes disposing a plurality of light-emitting diode (LED) chips on a carrier, wherein gaps are between the LED chips. The method includes forming a film on the LED chips and the carrier, and transferring at least one of the LED chips onto a first substrate, wherein the film is disconnected in the gaps adjacent to the at least one LED chip during the transferring the at least one of the LED chips onto the first substrate.