Micro-LED Optical Component with Integrated Substrate Lens
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Solution Overview
Problem
Existing optical components for micro-scale light-emitting diodes (LEDs) face challenges in integrating suitable optical structures due to the use of large LEDs and optical elements, which are not suitable for small-scale devices, leading to inefficiencies in light emission and distribution.
Innovation Solution
The development of a micro-scale LED optical component that includes a component substrate with an LED structure and an optical element, where the LED structure comprises a micro-LED and a broken tether, and the optical element is integrated or in contact with the substrate, allowing for efficient light emission and redirection, with the optical element being at least three times greater in extent than the LED's light-emitting area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If large LEDs and optical elements are used, then light emission and distribution can be achieved, but the devices are not suitable for micro-scale applications and have reduced efficiency
Solution Approach 1:
The patent applies parameter changes by scaling down the LED and optical element dimensions to micro-scale while maintaining their functional relationship. The LED active region is reduced to less than 10 micrometers, and the optical element is proportionally scaled, changing the size parameters to enable micro-scale fabrication while preserving light emission efficiency through maintained geometric relationships.
Solution Approach 2:
The patent implements local quality by creating a highly integrated structure where the optical element is positioned in direct contact with or extremely close to the LED active region. This localized configuration ensures that light is efficiently coupled into the optical element at the point of emission, maximizing light extraction efficiency in the micro-scale device.
2Productivity
If optical structures are added to avoid light trapping, then light emission efficiency improves, but device complexity increases
Solution Approach 1:
The patent merges the LED structure with the optical element by positioning them in direct contact or extreme proximity, effectively combining the light source and optical manipulation functions into a single integrated unit. This merging eliminates the need for separate mounting structures, alignment mechanisms, and intermediate optical components, thereby improving light emission efficiency while minimizing device complexity.
Solution Approach 2:
The patent employs a nested configuration where the optical element is positioned within or immediately adjacent to the LED structure footprint. The optical element may be embedded in the substrate beneath the LED or positioned in a cavity formed around the LED, creating a compact nested arrangement that achieves efficient light coupling without adding lateral complexity to the device layout.
3Volume of moving object
If micro-scale LEDs are used, then device size is reduced for small-scale applications, but integration of optical components becomes difficult
Solution Approach 1:
The patent transitions from lateral integration to vertical integration by positioning the optical element in the depth dimension beneath or above the LED structure. This dimensional shift allows optical components to be integrated in the z-direction rather than requiring lateral space, enabling micro-scale device footprint while maintaining ease of manufacture through vertical stacking of components.
Solution Approach 2:
The patent segments the device into distinct functional layers with the optical element forming a separate layer from the LED structure. This segmentation allows each component to be optimized and fabricated independently using appropriate micro-fabrication techniques for its layer, then integrated through vertical assembly, thereby simplifying the overall integration process for micro-scale devices.
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 solution enables efficient light emission with reduced divergence, suitable for small-scale applications such as medical and display uses, providing well-defined light emission and improved optical performance by positioning the LED's light-emitting area at the focal point of the optical element.
Implementation Method 1
one or more refractive lenses
Implementation Method 2
a reflector
Implementation Method 3
a diffraction grating
Implementation Method 4
light-emitting diodes (LEDs)
Data Source
AI summary
A light-emitting diode (LED) optical component comprises a component substrate and an disposed on the component substrate. The LED emits light when provided with electrical power. An optical element is disposed at least partly in contact with the component substrate such that at least a portion of the emitted light is incident on the optical element. A second optical element can optionally be disposed between the LED and the component substrate or on a side of the component substrate opposite the LED. An LED optical system includes a system substrate on which one or more LED optical components are disposed. The system substrate can be or include one or more optical elements.