Micro LED Molding Structure for Low-Glare Color Stability

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Solution Overview

Problem

Micro LED displays face challenges in transferring small micro LEDs to a circuit board and protecting them without causing optical distortion or loss of luminance, while also improving image quality.

Innovation Solution

A light emitting module is designed with a molding member that includes a black first molding layer covering the unit pixels and a transparent second molding layer, along with an anti-glare layer, to enhance durability and prevent color tone changes and luminance loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single transparent molding layer is used to protect micro LEDs, then the micro LEDs are physically protected, but optical distortion and luminance loss occur

Engineering Contradiction:

Improvephysical protection of micro LEDsVSAvoidluminance loss

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

The molding member is divided into multiple layers: a first molding layer (black, light-absorbing) and a second molding layer (transparent, optically clear). This segmentation allows each layer to perform its specialized function - the first layer prevents light leakage and the second layer provides optical clarity, thereby protecting the micro LEDs while minimizing luminance loss and optical distortion

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite material structure by combining a black molding material (first molding layer) with a transparent molding material (second molding layer). This composite approach integrates the light-absorbing properties of the first layer with the optical transparency of the second layer, achieving both physical protection and optical quality simultaneously

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If a black molding layer is added to prevent color tone changes, then color accuracy is improved, but the structure becomes more complex

Engineering Contradiction:

Improvecolor tone stabilityVSAvoidmolding member structure

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The molding member is segmented into functional layers: the first molding layer (black) specifically addresses color tone stability by absorbing stray light, while the second molding layer (transparent) maintains optical clarity. This functional segmentation achieves color accuracy without requiring a completely redesign of the protection structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first molding layer serves multiple functions: it prevents color tone changes by absorbing stray light, provides structural support, and creates a foundation for the second molding layer. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250151478A1Light emitting module and method of manufacturing the same and display apparatus having the same

Publication Date: 2025.05.08 SEOUL SEMICONDUCTOR

AI summary

A light emitting module including a circuit board, a plurality of unit pixels arranged on the circuit board, a molding member covering the unit pixels, and an anti-glare layer disposed on the molding member, in which the molding member includes a first molding layer at least partially covering each of the unit pixels, and a second molding layer covering the first molding layer.