Light Blocking Layer with Regular Openings for LED Uniformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in creating a display module with improved contrast ratio and uniform luminance is exacerbated by arrangement errors in micro LEDs, leading to irregular intervals and non-uniform light emission.
Innovation Solution
A display module design featuring a substrate with micro LEDs and a light blocking layer that covers and fills the intervals between LEDs, with openings that expose the top surface of each LED, ensuring regular intervals and uniform light emission, and includes a method of manufacturing this module using a photo resist layer and mask to form the openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If micro LEDs are disposed on a substrate to implement various colors, then color display capability is improved, but arrangement errors occur leading to irregular intervals and non-uniform luminance
Solution Approach 1:
A light blocking layer is introduced as an intermediary component between the substrate and the micro LEDs. This layer includes openings positioned at regular intervals that correspond to the ideal display pattern, allowing light to pass through only at these predetermined locations. The light blocking layer mediates the irregular LED arrangement by blocking light from LEDs at incorrect positions and allowing light from LEDs at correct positions, thereby achieving uniform luminance and regular intervals despite manufacturing variations in LED placement
2Manufacturing precision
If a light blocking layer is used to ensure regular light emission intervals, then uniform luminance is improved, but manufacturing complexity increases
Solution Approach 1:
The light blocking layer is designed with a porous structure containing multiple openings at regular intervals. Rather than requiring precise placement of each micro LED, the porous light blocking layer provides a predetermined regular pattern through which light can pass. This approach simplifies the overall manufacturing process by decoupling the regularity requirement from the LED placement process, allowing LEDs to be arranged more freely while still achieving uniform luminance through the structured openings
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 enhances the contrast ratio and uniformity of luminance by ensuring regular light emission intervals, addressing the issue of arrangement errors and improving display performance.
Implementation Method 1
a light blocking layer that covers the plurality of LEDs, and fills intervals among the plurality of LEDs
Implementation Method 2
a method of manufacturing this module using a photo resist layer and mask to form the openings
Data Source
AI summary
A display module includes a substrate, a plurality of LEDs that are disposed on the substrate and irradiate light, and a light blocking layer that covers the plurality of LEDs, and fills intervals among the plurality of LEDs, each interval of the intervals being a distance between two adjacent LEDs of the plurality of LEDs, and wherein the light blocking layer includes a plurality of openings formed such that a top surface of each of the plurality of LEDs is exposed.