Micro LED Molding Structure for Color Stability and Low Glare

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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 developed 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

1Device complexity

If a single-layer molding member is used to cover micro LEDs, then the structure is simple, but optical distortion and luminance loss occur

Engineering Contradiction:

Improvemolding member structureVSAvoidoptical quality

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The molding member is divided into multiple layers (first molding layer and second molding layer) with different functions. The first layer provides mechanical protection and color uniformity, while the second layer optimizes optical properties, thereby resolving the contradiction between structural simplicity and optical quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite molding layers with different material properties. The first molding layer may have different refractive index and mechanical properties compared to the second molding layer, allowing each layer to be optimized for its specific function while together providing superior optical performance.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If micro LEDs are mounted on circuit board without protection, then transfer is easier, but they are vulnerable to damage and optical degradation

Engineering Contradiction:

Improvemicro LED transferVSAvoidmicro LED protection

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The molding member is designed to provide protective cushioning to micro LEDs before they are fully integrated into the display device. This pre-protection mechanism shields the fragile micro LEDs from mechanical damage during and after the mounting process, resolving the contradiction between ease of transfer and protection needs.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Illumination intensity

If a transparent molding layer is used alone, then luminance is maintained, but color tone changes occur

Engineering Contradiction:

ImproveluminanceVSAvoidcolor consistency

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

Different regions of the molding structure are assigned different optical properties. The first molding layer may have properties that prevent color tone changes, while the second molding layer is optimized for luminance maintenance. This local differentiation allows each layer to address specific optical issues without compromising overall performance.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12218286B2Light emitting module and method of manufacturing the same and display apparatus having the same

Publication Date: 2025.02.04 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.