Micro LED Molding Layer Structure for Luminance and Color Uniformity

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Solution Overview

Problem

Micro LED displays face challenges in maintaining visibility and minimizing luminance loss and color change due to the circuit board on which the light emitting diodes are mounted, requiring techniques to improve image quality.

Innovation Solution

A light emitting module with a structure comprising a light diffusion layer and a black molding layer is manufactured by laminating films on a module substrate, forming a molding layer around unit pixels, and cutting edges to minimize luminance loss and color change, using thermosetting and photosensitive materials for the layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a micro LED is mounted on a circuit board, then the display can be made compact and thin, but luminance loss and color change occur due to the circuit board

Engineering Contradiction:

Improvedisplay thicknessVSAvoidluminance

Core Design Contradiction:

Volume of moving objectVSIllumination intensity

Solution Approach 1:

A molding layer is introduced as an intermediary component between the circuit board and the micro LED. This molding layer includes a light diffusion layer and a black molding layer that work together to prevent luminance loss and color change while maintaining the compact and thin display structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The molding layer is constructed using composite materials with different optical properties - a light diffusion layer for scattering and uniformizing light, and a black molding layer for absorbing stray light. This composite structure resolves the contradiction by maintaining both thinness and luminance performance.

Inventive Principle:

Principle #40Composite materials

2Volume of moving object

If a micro LED is mounted on a circuit board, then the display can be made compact and thin, but color change occurs due to the circuit board

Engineering Contradiction:

Improvedisplay thicknessVSAvoidcolor uniformity

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The molding layer serves as a mediator that corrects color uniformity issues. The light diffusion layer scatters light to eliminate color hotspots, while the black molding layer absorbs stray light that would cause color contamination, thereby maintaining color uniformity in the thin display structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Different regions of the molding layer have different functions - the light diffusion layer addresses local color uniformity issues by scattering light, while the black molding layer addresses local stray light issues by absorption. This localized quality approach resolves the color uniformity problem while maintaining thinness.

Inventive Principle:

Principle #3Local quality

3Illumination intensity

If a light diffusion layer and black molding layer are added, then luminance loss is reduced, but device complexity increases

Engineering Contradiction:

ImproveluminanceVSAvoidmolding layer structure

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The light diffusion layer and black molding layer are merged into a single integrated molding layer structure that is formed in one manufacturing process. This combining approach reduces device complexity while maintaining the luminance benefits of both layers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molding layer performs multiple functions simultaneously - it provides structural support, diffuses light to prevent luminance loss, and absorbs stray light through the black layer. This multi-functionality reduces the need for separate components, thereby reducing overall device complexity while maintaining luminance performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enhances visibility and reduces luminance loss by diffusing and absorbing light effectively, improving image quality and maintaining uniformity in the display apparatus.

Implementation Method 1

forming a molding layer to surround side surfaces of the plurality of unit pixels by disposing the laminated light diffusion film and the black film on the module substrate... the molding layer includes a light diffusion layer and a black molding layer

Methodology Applied

Scientific EffectLight diffusion: Scattering

Implementation Method 2

The third LED stack may emit light having a shorter wavelength than that of the first LED stack and emit light having a longer wavelength than that of the second LED stack... a black molding layer disposed on the light diffusion layer

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Data Source

PatentUS20250351630A1Light emitting module having molding layer including light diffusion layer and black molding layer and display device having the same

Publication Date: 2025.11.13 SEOUL VIOSYS CO LTD

AI summary

A method of manufacturing a light emitting module includes mounting a plurality of unit pixels on a module substrate, thermally curing a light diffusion film and a black film, laminating the light diffusion film and the black film, forming a molding layer to surround side surfaces of the plurality of unit pixels by disposing the laminated light diffusion film and the black film on the module substrate, and pressing the light diffusion film and the black film; and cutting and removing edges of the module substrate and the molding layer. The molding layer includes a light diffusion layer and a black molding layer disposed on the light diffusion layer.