Micro-LED Display Module with Reflective and Light Blocking Layers
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Solution Overview
Problem
Micro-LED display screens face inefficiencies in light utilization and increased power consumption due to lateral light emission, and heat generated during light emission can damage components.
Innovation Solution
A display module design incorporating a reflective layer to redirect lateral light emissions towards the upper surface, enhancing luminance and using a light blocking layer to improve contrast, along with a manufacturing process that includes forming a reflective layer around micro-LEDs to efficiently conduct heat and stabilize the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple planar substrate is used, then manufacturing is easy and cost is low, but color uniformity deteriorates due to thermal expansion differences
Solution Approach 1:
The substrate is divided into a first substrate and a second substrate that are bonded together to form a laminated structure. Each substrate can be manufactured independently with appropriate thermal expansion characteristics, and their combination creates an integrated substrate with improved overall thermal stability and color uniformity while maintaining manufacturing simplicity
Solution Approach 2:
The patent uses a laminated composite substrate structure where two different substrates are bonded together. This composite structure combines the advantages of different materials to achieve balanced thermal expansion properties, ensuring color uniformity across the display panel while keeping the manufacturing process straightforward
2Manufacturing precision
If a laminated substrate structure is used to improve color uniformity, then color uniformity is improved, but device complexity increases
Solution Approach 1:
The substrate is divided into a first substrate and a second substrate that are bonded together to form a laminated structure. Each substrate can be manufactured independently with appropriate thermal expansion characteristics, and their combination creates an integrated substrate with improved overall thermal stability and color uniformity while maintaining manufacturing simplicity
Solution Approach 2:
The patent ensures that the laminated substrate structure provides homogeneous thermal expansion characteristics across the entire substrate area. By carefully selecting and bonding substrates with complementary properties, the structure achieves uniform thermal behavior that prevents color shifts, simplifying the overall device design compared to using complex single-substrate solutions
3Device complexity
If organic EL materials are used, then device complexity is reduced compared to inorganic materials, but lifetime and stability deteriorate due to sensitivity to moisture and oxygen
Solution Approach 1:
The patent introduces an intermediate encapsulation layer between the organic EL material and the external environment. This intermediary layer acts as a barrier to moisture and oxygen, protecting the sensitive organic materials while allowing the device to maintain its simpler organic-based structure. The encapsulation layer serves as a mediator that isolates the organic EL layer from harmful environmental factors
Solution Approach 2:
The patent employs thin-film encapsulation layers that provide adequate protection against moisture and oxygen for the organic EL materials. These relatively simple, thin protective layers are sufficient to extend the lifetime of organic EL devices without requiring complex multi-layer encapsulation structures, balancing protection needs with device simplicity
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 increases light utilization and luminance, reduces power consumption, and effectively manages heat, thereby improving the performance and lifespan of micro-LED display screens.
Implementation Method 1
a first organic EL layer which emits blue light
Implementation Method 2
a second organic EL layer which emits green light
Data Source
Figure 1
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AI summary
A display module is disclosed. The display module includes a substrate, a plurality of micro light-emitting diodes (micro-LEDs) disposed on the substrate and configured to radiate light, a reflective layer surrounding a lateral surface of each of the plurality of micro-LEDs, and a light blocking layer disposed on the reflective layer.