Micro LED Color Conversion Layer Imprinting for Optical Efficiency

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Solution Overview

Problem

Existing display technologies, such as liquid crystal panels and OLED panels, face challenges including slow response time, high power consumption, vulnerability to burn-in, and limited compactification due to the need for backlights.

Innovation Solution

A display apparatus utilizing a micro LED panel with inorganic light-emitting devices, where a color conversion material is positioned in a predetermined shape by imprinting a low refractive layer, enhancing optical efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If a liquid crystal panel is used, then the panel can display images, but the response time is slow and power consumption is high

Engineering Contradiction:

Improveresponse timeVSAvoidpower consumption

Core Design Contradiction:

SpeedVSUse of energy by moving object

Solution Approach 1:

The patent transitions from liquid crystal technology to micro LED technology, fundamentally changing the operating parameters and mechanism. Micro LEDs are self-emissive devices that convert electrical energy directly to light, eliminating the need for backlight units and liquid crystal modulation, thereby achieving faster response times and lower power consumption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical liquid crystal switching mechanism with solid-state micro LED light emission. This substitution eliminates the need for liquid crystal molecules to physically reorient, enabling instantaneous response and significantly reducing energy consumption by eliminating the backlight unit

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Length of stationary object

If an OLED panel is used, then the panel can be implemented in a thinner configuration, but the panel is vulnerable to burn-in phenomenon

Engineering Contradiction:

Improvepanel thicknessVSAvoidburn-in resistance

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

The patent changes the material composition from organic compounds (OLED) to inorganic semiconductor materials (micro LED). This fundamental parameter change provides superior reliability and burn-in resistance while maintaining thin form factor, as inorganic materials have longer operational lifetimes and do not suffer from the same degradation mechanisms as organic materials

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs inorganic semiconductor materials with specific optical and electrical properties to create micro LED devices that combine the benefits of thin form factor with enhanced reliability. The inorganic material composition provides both the structural integrity needed for thin designs and the stability required to prevent burn-in phenomena

Inventive Principle:

Principle #40Composite materials

3Volume of moving object

If a liquid crystal panel with backlight is used, then the panel can display images, but the panel cannot be compactified

Engineering Contradiction:

Improvepanel thicknessVSAvoidmanufacturing complexity

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The patent extracts and removes the backlight unit from the display structure, replacing it with self-emissive micro LED elements. This extraction eliminates the need for complex backlight components including light guides, diffusers, and reflectors, thereby enabling panel compactification while actually simplifying the overall manufacturing process

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using a backlight unit that illuminates the display from behind, the patent inverts the approach by having the display elements themselves emit light directly toward the viewer. This inversion eliminates the need for complex light management components and enables significant thinning of the panel structure

Inventive Principle:

Principle #13The other way round (Inversion)

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 micro LED panel offers improved optical efficiency, better contrast, response time, and energy efficiency compared to traditional LCD panels, while avoiding burn-in issues associated with OLEDs.

Implementation Method 1

imprinting a low refractive layer

Methodology Applied

Scientific EffectImprinting:

Implementation Method 2

an inorganic light-emitting device is positioned on the light source substrate, and the inorganic light-emitting device faces the color layer

Methodology Applied

Scientific EffectLight emission: Light Emitting Diode

Data Source

PatentUS20250133880A1Display apparatus and method of manufacturing the same

Publication Date: 2025.04.24 SAMSUNG ELECTRONICS CO LTD

AI summary

Provided is a display module and a method of manufacturing same. The method includes: forming a color layer on a base substrate; and adhering a light source substrate to the color layer, wherein an inorganic light-emitting device is positioned on the light source substrate, and the inorganic light-emitting device faces the color layer, and wherein the forming the color layer includes: positioning a color filter on the base substrate; positioning a low refractive layer on the color filter; imprinting the low refractive layer; and positioning a color conversion material on the imprinted low refractive layer.