Integrated Micro Lens Micro LED Panel for Simpler Fabrication
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Solution Overview
Problem
The conventional micro LED panel manufacturing process is complex and difficult due to the need for forming micro lenses, which increases process complexity and cost.
Innovation Solution
A micro LED display panel with a micro LED array area featuring micro LED structures that include a first type epitaxial layer, a light emitting layer, and a second type epitaxial layer with an integrated micro lens structure and bottom structure, simplifying the manufacturing process by etching these structures from a single epitaxial layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional micro lens is provided on a micro LED and formed through separate processes, then the light emitting angle can be adjusted, but the process complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the micro lens structure and the bottom structure into a single integrated structure formed from the second type epitaxial layer. This merging eliminates the need for separate formation processes for the micro lens and bottom structure, thereby reducing manufacturing process complexity while maintaining the light emitting angle adjustment function
Solution Approach 2:
The second type epitaxial layer serves multiple functions: it provides the bottom structure for electrical connection and support, and simultaneously forms the micro lens structure for light emission control. This multi-functionality reduces the number of separate components and processes needed in the micro LED manufacturing
2Ease of operation
If separate micro lens formation processes are used, then light emission control is achieved, but manufacturing cost increases
Solution Approach 1:
By merging the micro lens formation with the epitaxial layer growth process, the patent eliminates additional fabrication steps such as separate lithography, etching, and deposition processes that would be required for traditional micro lens formation. This integration significantly reduces manufacturing cost while maintaining light emission control capability
Solution Approach 2:
The micro lens structure is formed preliminarily during the epitaxial layer growth process itself, rather than as a subsequent separate step. This preliminary action incorporates the light emission control function into the base manufacturing process, avoiding additional costly fabrication 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
The integrated micro lens structure simplifies the manufacturing process, reduces costs, and improves light emission performance by increasing light emission efficiency by 15% to 18% compared to other micro lenses.
Implementation Method 1
a micro lens is provided on a micro LED and used for adjusting the light emitting angle
Data Source
AI summary
A micro LED display panel includes a micro LED array area including a plurality of micro LED structures. Each of the micro LED structures includes: a first type epitaxial layer; a light emitting layer formed on the first type epitaxial layer; and a second type epitaxial layer formed on the light emitting layer. The second type epitaxial layer includes: a micro lens structure and a bottom structure, the micro lens structure and the bottom structure being an integrative structure.