Maskless Color Conversion Layer Patterning for Micro-LED Displays
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Solution Overview
Problem
The fabrication of high-resolution display devices using micro-LEDs requires high-efficiency micro-LED chips and advanced transfer technologies, and existing methods for patterning color conversion layers often involve masks, increasing production costs and complexity.
Innovation Solution
A method for manufacturing display devices that patterns color conversion layers without using a mask, employing a semiconductor layer as a partition wall and using quantum dots or phosphors, which simplifies the design of scan and data drivers and reduces residues, enabling high-resolution displays with improved process yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask is used for patterning color conversion layers, then patterning precision can be maintained, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent extracts and removes the mask from the patterning process. Instead of using a mask to define the color conversion layer pattern, the invention uses a self-aligned approach where the color conversion layer is formed directly over the LED structure, eliminating the need for separate mask alignment steps and reducing process complexity while maintaining precision.
Solution Approach 2:
The patent implements self-service patterning where the LED structure itself serves as the alignment reference for the color conversion layer. The color conversion layer is formed to automatically align with the LED active region through conformal deposition or self-aligned processes, eliminating the need for external mask guidance and simplifying the manufacturing process.
2Manufacturing precision
If micro-LED chips are used for high-resolution displays, then display resolution is improved, but transfer technology complexity and production cost increase
Solution Approach 1:
The patent merges the LED chip formation and color conversion layer deposition into a single integrated process. Both the micro-LED chips and color conversion layers are formed on the same substrate simultaneously, eliminating the need for separate transfer operations and reducing production complexity while achieving high display resolution.
Solution Approach 2:
The patent segments the display into multiple subpixels with different color conversion layers (red, green, blue) that are formed in distinct regions. This segmentation allows each color channel to be independently optimized while maintaining overall high resolution, and the segmented structure facilitates simplified manufacturing compared to transferring complete micro-LED chips.
3Use of energy by moving object
If multiple color conversion layers are stacked, then color accuracy and light extraction efficiency are improved, but manufacturing process complexity increases
Solution Approach 1:
The patent uses periodic action in the form of sequential deposition and selective removal steps to form multiple color conversion layers. Each layer is deposited, patterned, and then partially removed to create the desired color filter structure. This periodic process sequence enables precise control over layer thickness and pattern while maintaining manufacturing efficiency through repetition of standardized steps.
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 reduces manufacturing expenses, simplifies driver designs, minimizes residues, and achieves high-resolution displays with enhanced light extraction efficiency, such as 5000 ppi or higher, while eliminating the need for high-level transfer technologies.
Implementation Method 1
each of the plurality of light emitting elements including a second semiconductor layer provided under the first semiconductor layer and an active layer interposed between the first semiconductor layer
Implementation Method 2
employing a semiconductor layer as a partition wall and using quantum dots or phosphors
Data Source
AI summary
A display device includes: a plurality of light emitting elements including a first semiconductor layer, each of the plurality of light emitting elements including a second semiconductor layer provided under the first semiconductor layer and an active layer interposed between the first semiconductor layer; a plurality of partition walls extending from the first semiconductor layer; and a plurality of color conversion layers provided on the plurality of light emitting elements in correspondence with the plurality of light emitting elements and spaced apart from each other by the plurality of partition walls, each of the plurality of color conversion layers including a first color conversion layer and a second color conversion layer stacked on the first color conversion layer.