Light Emitting Cell Shielding Layout for Color Reproducibility
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Solution Overview
Problem
Existing light emitting devices face challenges in achieving excellent color reproducibility and waste reduction during the manufacturing process.
Innovation Solution
A method for manufacturing a light emitting device involves forming multiple light emitting cells on a substrate, selectively bonding them onto another substrate, and using a light shielding layer to prevent color mixing, while also reducing wafer waste through laser lift-off processes and precise cutting techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If light emitting cells are densely arranged on a wafer to increase productivity, then manufacturing efficiency improves, but color mixing between adjacent cells occurs reducing color reproducibility
Solution Approach 1:
A light shielding layer is introduced as an intermediary element between adjacent light emitting cells. This layer prevents light from one cell from interfering with adjacent cells, thereby maintaining color reproducibility while allowing dense cell arrangement for high productivity.
Solution Approach 2:
The light shielding layer is segmented into discrete regions corresponding to each light emitting cell. This segmentation allows the shielding structure to be precisely positioned between cells without interfering with the optical output of individual cells, enabling both high density arrangement and color accuracy.
2Ease of manufacture
If conventional wafer processing is used without selective release, then manufacturing process is simple, but large portions of the wafer are wasted
Solution Approach 1:
Release holes are pre-formed in the wafer substrate before the light emitting cells are fully processed. This preliminary action allows for selective release of individual cells or groups of cells later in the process, maximizing wafer utilization while maintaining manufacturing simplicity.
Solution Approach 2:
The wafer substrate is modified locally at specific positions where release holes are formed. This localized modification allows selective release of only the necessary portions of the wafer, minimizing waste while keeping the overall manufacturing process simple and scalable.
3Ease of manufacture
If light shielding layer is added between cells to prevent color mixing, then color reproducibility improves, but device complexity increases
Solution Approach 1:
The light shielding layer is formed with uniform material composition and consistent thickness across the entire wafer. This homogeneous structure simplifies the manufacturing process and reduces complexity, while still effectively preventing color mixing between adjacent cells.
Solution Approach 2:
The light shielding layer serves multiple functions simultaneously: it prevents color mixing between cells, provides mechanical support for the cell array, and can be integrated with the mounting substrate structure. This multi-functionality reduces the need for additional separate components, thereby reducing overall device complexity.
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 method enhances color reproducibility and minimizes waste by ensuring precise spacing and shielding between cells, leading to improved color accuracy and efficient manufacturing.
Implementation Method 1
separating the first light emitting cells from the first substrate by selectively performing a laser lift-off process at portions of the first substrate corresponding to the first light emitting cells
Data Source
AI summary
A light emitting device including a substrate, at least two light emitting cells disposed on the substrate, a light shielding layer disposed between the at least two light emitting cells, and having openings each exposing one surface of each of the light emitting cells, and bonding parts filling the openings, and disposed between the light emitting cells and the substrate.