Light-emitting module with integrated optical layer for simplified manufacturing

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Solution Overview

Problem

Conventional light-emitting modules require additional processes for protective layers, leading to complex manufacturing and potential decreases in black contrast and white balance due to electrode reflection, especially in white pixels.

Innovation Solution

A light-emitting module design featuring light-emitting elements with a protective layer and color changing members, where an optical layer with a curved shape covers both, simplifying the manufacturing process and preventing reflection by forming concave or convex shapes depending on pixel types, and optionally including a transparent or inorganic material and antireflection films.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a protective layer is provided around the color filter to prevent reliability decrease, then reliability is improved, but manufacturing process becomes complicated

Engineering Contradiction:

ImprovereliabilityVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the protective layer and optical layer into a single integrated layer structure. The protective layer is formed as part of the same coating process that creates the optical layer, eliminating the need for separate protective layer formation steps while maintaining both protection and optical functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The optical layer is designed to serve multiple functions simultaneously: it acts as both the protective barrier layer and the optical conditioning layer. This multi-functional design reduces the total number of layers needed while achieving both reliability protection and optical performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a protective layer is added to prevent reliability issues, then reliability is improved, but the number of manufacturing steps increases

Engineering Contradiction:

ImprovereliabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The protective layer formation is merged with the optical layer formation in a single coating process. This integration reduces the total number of manufacturing steps while ensuring both protective and optical functions are achieved simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The protective functionality is built into the optical layer from the beginning of the layer formation process. By incorporating protection features during the initial coating step rather than adding them later, the manufacturing process is streamlined and productivity is improved.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If conventional layer structure is used, then manufacturing is simpler, but black contrast and white balance decrease due to electrode reflection

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidblack contrast and white balance

Core Design Contradiction:

Ease of manufactureVSIllumination intensity

Solution Approach 1:

The optical layer is designed with different local properties at different pixel locations. At white pixel locations, the optical layer has specific optical characteristics that prevent electrode reflection, while at colored pixel locations, the optical layer works in conjunction with color filters. This localized optimization maintains manufacturing simplicity while improving display quality.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent addresses the harmful effect of electrode reflection by incorporating optical control features directly into the necessary protective/optical layer. The same layer that provides protection also contains optical structures that convert the potentially harmful reflection into beneficial light control, improving both black contrast and white balance.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 design simplifies the manufacturing process, enhances light emission efficiency, and maintains black contrast and white balance by using a single process to form both the barrier and lens functions of the optical layer, reducing the need for additional steps and improving optical performance.

Implementation Method 1

an optical layer that covers the color changing members and the protective layer, and condenses or scatters light with a curved shape

Methodology Applied

Scientific EffectLight condensation and scattering: Lens

Data Source

PatentUS11437603B2Light-emitting module, display device, and methods for manufacturing with color changing members disposed at non-white pixels

Publication Date: 2022.09.06 SONY SEMICON SOLUTIONS CORP

AI summary

To simplify a process of manufacturing a light-emitting module for displaying an image.The light-emitting module includes light-emitting elements, a protective layer, color changing members, and an optical layer. The light-emitting elements are arranged on a substrate. The protective layer is formed in such a way as to cover the light-emitting elements. The color changing members are disposed in such a way as to correspond to at least some of the light-emitting elements with the protective layer interposed between the color changing members and the some of the light-emitting elements. The optical layer is formed in such a way as to cover the color changing members and the protective layer. This optical layer condenses or scatters light with its curved shape.