Micro LED Arrays with Phosphor Film for Color Control

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Solution Overview

Problem

Conventional micro LED technology is limited by fixed light color output, requiring additional phosphor powders for color variation, which is not compatible with new micro LED designs and leads to inefficiencies and limited color choices.

Innovation Solution

An LED lighting module with a phosphor film covering the entire surface of micro LED arrays, allowing for independent addressing and control of light colors, using a transparent substrate with defined light emitting regions and uniformly distributed phosphor powder for enhanced color expression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional phosphor powder packaging methods are used with micro LEDs, then color variation is achieved, but the structure becomes complex and incompatible with new micro LED designs

Engineering Contradiction:

Improvecolor variation capabilityVSAvoidpackaging structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the phosphor powder with the gel matrix to form an integrated phosphor gel layer directly on the micro LED chip surface. This integration eliminates the need for separate phosphor packaging structures, reducing complexity while maintaining color variation capability through the gel's light-transmitting properties

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a thin gel film structure that covers the micro LED chip surface. This flexible thin film contains the phosphor powder and provides a simple, compatible structure for new micro LED designs while enabling color expression without complex packaging

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If multiple phosphor powders are packaged on micro LED surfaces, then different light colors are produced, but light loss increases due to multiple packaging layers

Engineering Contradiction:

Improvelight color expressionVSAvoidlight loss

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

By combining multiple phosphor powders into a single integrated gel layer on the micro LED surface, the patent reduces the number of separate packaging layers. This merging minimizes light absorption and scattering that would occur with multiple discrete packages, thereby reducing light loss while maintaining diverse color expression

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thin gel film structure serves as a single-layer packaging that contains multiple phosphor powders. This thin film approach reduces light path length and material absorption compared to thicker multi-layer packages, minimizing light loss while enabling rich color expression

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If conventional flip chip or CSP packaging is used, then light color control is achieved, but these methods cannot be directly applied to new micro LEDs

Engineering Contradiction:

Improvelight color controlVSAvoidmanufacturing compatibility

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent segments the packaging function into a separate gel matrix layer that can be independently applied to the micro LED chip surface. This segmentation allows the gel layer to be optimized for compatibility with new micro LED designs while still providing the light color control functions traditionally achieved through integrated flip chip or CSP packaging

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The gel matrix acts as an intermediary material between the micro LED chip and the phosphor powders. This intermediary layer provides a compatible interface for new micro LED designs while enabling light color control through the gel's optical properties and its ability to contain and distribute phosphor particles

Inventive Principle:

Principle #24Intermediary (Mediator)

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 micro LEDs to produce a wide range of colors, improving display performance, reducing light loss, and simplifying installation, while maintaining a thin module design, thus overcoming the limitations of conventional micro LED technologies.

Implementation Method 1

at least one phosphor powder being is disposed on a part or the whole of a surface of the light emitting regions... such that the light emitting regions provide different light color expressions

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Data Source

PatentUS11408591B2LED lighting module with micro LED arrays and phosphor film

Publication Date: 2022.08.09 UNITY OPTO TECH CO LTD

AI summary

An LED lighting module with micro led arrays and phosphor film is disclosed. The LED lighting module includes a plurality of micro LED arrays and a phosphor film. The micro LED arrays are respectively composed of at least one micro LED. The phosphor film is disposed on one side of the micro LED arrays; and the phosphor film has a transparent substrate and is provided with a plurality of light emitting regions. The plurality of light emitting regions are arranged adjacent to each other and into a matrix form, and are set corresponding to the micro LED arrays collimation respectively. A part or the whole of the surface of the plurality of light emitting regions is provided with at least one type of phosphor powder.