LED Pixel Sidewall Formation Using Expandable Film Transfer
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Solution Overview
Problem
Precision control lighting applications require the development of small addressable LED pixel systems with non-conventional components and manufacturing processes, particularly for high-brightness light emitting diodes across the visible spectrum, where existing methods struggle to efficiently produce and integrate wavelength conversion elements and optical isolation materials.
Innovation Solution
The use of expandable films that can expand and contract to apply sidewall materials and wavelength converting layers onto LED arrays, allowing for precise alignment and integration of optical isolation materials between pixels, enabling efficient light emission and optical control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used for small LED pixel systems, then production is simpler, but manufacturing precision and alignment of optical materials deteriorate
Solution Approach 1:
A release film is introduced as an intermediary carrier during the manufacturing process. The release film allows multiple optical materials to be deposited and patterned separately with precise alignment, then transferred together as a complete assembly to the LED pixel array. This mediator enables high-precision manufacturing without requiring complex in-situ alignment equipment.
Solution Approach 2:
Optical materials are deposited and patterned on the release film before being transferred to the LED pixel array. This preliminary action allows all optical components to be pre-aligned and pre-assembled with high precision on the release film, eliminating the need for complex real-time alignment during final assembly.
2Area of moving object
If pixel size is reduced for high-resolution displays, then display density improves, but integration of optical materials becomes more difficult
Solution Approach 1:
The release film serves as a mediator that accommodates multiple optical materials during deposition and patterning. Even as pixel dimensions shrink, the release film provides a stable platform for integrating wavelength converting layers, optical isolation materials, and other components, then transferring the complete assembly to the miniaturized LED pixels.
Solution Approach 2:
Multiple optical materials and layers are combined into a single integrated assembly on the release film before transfer to the LED pixel array. This merging approach allows all optical components to be manufactured and aligned together as one unit, simplifying the manufacturing process despite reduced pixel sizes.
3Productivity
If multiple optical materials are integrated for wavelength conversion and optical isolation, then light emission efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The release film acts as a mediator that enables the integration of multiple optical materials (wavelength converting layers, optical isolation materials) in a systematic manner. Each material can be deposited and patterned separately on the release film with precise control, then the complete multi-layer assembly is transferred to the LED pixels, achieving high light emission efficiency without proportionally increasing manufacturing complexity.
Solution Approach 2:
All optical materials are preliminarily deposited, patterned, and assembled on the release film before transfer to the LED pixel array. This preliminary integration allows multiple optical functions to be combined in advance, reducing the complexity of final assembly while maintaining high light emission efficiency through proper optical material integration.
Data Source
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AI summary
A first component with a first sidewall and a second component with a second sidewall may be mounted onto an expandable film such that an original distance X is the distance between the first sidewall and the second sidewall. The expandable film may be expanded such that an expanded distance Y is the distance between the first sidewall and the second sidewall and expanded distance Y is greater than original distance X. A first sidewall material may be applied within at least a part of a space between the first sidewall and the second sidewall. The expandable film may be expanded such that a contracted distance Z is the distance between the first sidewall and the second sidewall, and contracted distance Z is less than expanded distance Y.