Micro LED Lens Transfer Structure for Simpler Display Manufacturing

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Solution Overview

Problem

The manufacturing process of micro light emitting diode display apparatuses is complicated and costly due to the need for a photolithography process to form lenses after transferring micro light emitting diodes, which affects the reliability and lifespan of organic light emitting display devices.

Innovation Solution

A manufacturing method that simultaneously transfers micro light emitting diodes and lenses onto an array substrate using a stamp with concave portions, eliminating the need for a separate photolithography process to form lenses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a photolithography process is used to form lenses after transferring micro light emitting diodes, then the display apparatus achieves improved light extraction efficiency and viewing angle control, but the manufacturing process becomes complicated and manufacturing cost increases

Engineering Contradiction:

Improvelight extraction efficiencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming lenses on the stamp before transferring micro light emitting diodes. The stamp is prepared with lens-forming material in advance, and during the transfer process, the lenses are simultaneously formed and transferred along with the micro light emitting diodes. This eliminates the need for subsequent photolithography processes, simplifying the manufacturing workflow while achieving the required light extraction efficiency and viewing angle control.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the lens formation process with the micro light emitting diode transfer process into a single simultaneous operation. By integrating these two previously separate processes, the manufacturing steps are reduced, complexity is lowered, and production efficiency is improved while maintaining the optical performance benefits of having lenses on each micro light emitting diode.

Inventive Principle:

Principle #5Merging (Combining)

2Illumination intensity

Engineering Contradiction:

Improvelight extraction efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The stamp is prepared in advance with lens-forming material deposited in concave portions, creating pre-formed lenses before the transfer process. This preliminary preparation allows lenses to be formed simultaneously with micro light emitting diode transfer, eliminating costly subsequent photolithography steps and reducing overall manufacturing cost while maintaining light extraction efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses a stamp as a reusable template that copies the lens structure onto each micro light emitting diode position during transfer. This copying approach allows consistent lens formation across multiple devices using the same stamp, reducing per-unit manufacturing cost compared to individual photolithography processes for each device.

Inventive Principle:

Principle #26Copying

3Ease of manufacture

If micro light emitting diodes are transferred first and then lenses are formed by photolithography, then the manufacturing process follows conventional steps, but the process becomes complicated and time-consuming

Engineering Contradiction:

Improveconventional manufacturing processVSAvoidmanufacturing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent combines the micro light emitting diode transfer process and lens formation process into a single simultaneous operation. By merging these two sequential processes into one concurrent process, the total manufacturing time is reduced while maintaining the conventional ease of using established transfer techniques, eliminating the need for separate photolithography steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stamp is pre-prepared with lens-forming material in concave portions before the transfer process begins. This preliminary preparation enables lenses to be formed simultaneously with micro light emitting diode transfer, significantly reducing the total manufacturing time compared to sequential processes while maintaining compatibility with conventional manufacturing approaches.

Inventive Principle:

Principle #10Preliminary action

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 method simplifies the manufacturing process and reduces costs while improving light extraction efficiency and reducing power consumption by using lenses with a curved upper surface on each micro light emitting diode.

Implementation Method 1

a lens disposed on the micro light emitting diode

Methodology Applied

Scientific EffectLight extraction: Refraction

Data Source

PatentUS20250212569A1Display apparatus and manufacturing method of the same

Publication Date: 2025.06.26 LG DISPLAY CO LTD

AI summary

There is disclosed a display apparatus including a substrate, a first electrode and a second electrode that are disposed on the substrate, a bank layer disposed on the first electrode and the second electrode, the bank layer comprising an opening, a micro light emitting diode disposed inside the opening of the bank layer, a high refractive index layer disposed on the micro light emitting diode, an overcoat layer disposed on the high refractive index layer and having a lower refractive index than the high refractive index layer, and a fixation member disposed between the high refractive index layer and the bank layer.