Micro LED Display with Phosphor and Color Filter
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Solution Overview
Problem
Conventional micro-LED display manufacturing involves multiple time-consuming and technically challenging transfers of LED micro-devices, particularly for creating red, green, and blue arrays, due to the need for precise handling of small, high-density LED arrays.
Innovation Solution
A micro light-emitting diode display device and method that incorporates a substrate with blue-emitting micro-LEDs, a yellow phosphor layer, and a color filter layer with light-transmitting holes, allowing for simultaneous transfer and color display by exciting the phosphor layer with blue light, reducing the number of transfer steps and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple transfers are performed to create red, green, and blue LED arrays from separate substrates, then color display capability is achieved, but manufacturing time and technical difficulty increase significantly
Solution Approach 1:
The patent merges the transfer of red, green, and blue LED micro-devices into a single transfer operation by integrating multiple color LED arrays on one substrate. Instead of performing separate transfers for each color, the invention combines all color LED arrays into one unified transfer process, thereby achieving color display capability while significantly reducing manufacturing time and operational complexity.
Solution Approach 2:
The substrate is designed to serve multiple functions: it simultaneously supports red, green, and blue LED micro-devices, and acts as a single transfer target for all color arrays. This multi-functional substrate eliminates the need for multiple specialized substrates and transfers, resolving the contradiction between achieving color display versatility and minimizing manufacturing time.
2Manufacturing precision
If multiple precise transfers are performed for each LED color, then color accuracy is maintained, but technical difficulty and process complexity increase
Solution Approach 1:
The patent combines multiple precise transfer operations into a single transfer process. By integrating red, green, and blue LED arrays on one substrate with unified positioning structures, the invention maintains transfer precision for all color LEDs while reducing process complexity from multiple sequential transfers to one simultaneous transfer operation.
Solution Approach 2:
The substrate is segmented into distinct regions for red, green, and blue LED arrays, each with its own positioning structures. This segmentation allows each color region to be precisely positioned during the single transfer process, maintaining manufacturing precision while avoiding the complexity of multiple separate transfers.
3Adaptability or versatility
If separate substrates are used for each LED color, then color-specific optimization is achieved, but the number of transfer operations increases
Solution Approach 1:
The patent creates a universal substrate that accommodates red, green, and blue LED micro-devices simultaneously. This multi-functional substrate eliminates the need for separate color-specific substrates and transfers, achieving color-specific optimization through dedicated regions while reducing the number of transfer operations to just one.
Solution Approach 2:
The invention merges multiple color-specific substrates into a single integrated substrate. By combining red, green, and blue LED arrays on one substrate with appropriate positioning and spacing, the patent reduces the number of transfer operations from multiple separate transfers to one unified transfer, improving ease of operation.
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 approach enables a single-time transfer of micro-LEDs, simplifies the manufacturing process, and reduces technical difficulty, achieving a color display by controlling light intensity through the phosphor and filter layers, while maintaining high display reliability.
Implementation Method 1
a yellow phosphor layer disposed on a light-emitting side of the micro light-emitting diodes
Data Source
AI summary
The present invention discloses a micro light-emitting diode display device comprising a substrate, micro light-emitting diodes arrayed on an upper surface of a substrate for emitting blue light, a yellow phosphor layer disposed on a light-emitting side of the micro light-emitting diodes, and a color filter layer disposed on a light-emitting side of the yellow phosphor layer. The color filter layer comprises a red filter area, a green filter area, and a light-transmitting area. The yellow phosphor layer is provided with light-transmitting holes opened to its surface at intervals, and the light-transmitting holes are directly opposite to the light-transmitting area. The present invention further provides a method of manufacturing a micro light emitting diode display device. A color display purpose is achieved, which reduces the times of transferring the light-emitting diodes, simplifies the manufacturing process, and reduces technical difficulty for transferring micro LED.