Micro LED Projection Device Dichroic Prism Synthesis

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Solution Overview

Problem

Conventional projection devices require separate high-current lamps for sufficient brightness, leading to inflexibility and reduced optical efficiency, making it difficult to achieve high-resolution full-color displays in a compact structure.

Innovation Solution

A projection device utilizing a red, green, and blue micro LED panel configuration with a dichroic prism to synthesize light, along with a method that includes forming micro LED panels on GaAs substrates and flip-chip bonding onto silicon substrates, eliminating the need for separate light source lamps and avoiding the sapphire bonding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If separate high-current lamps are used for sufficient brightness, then illumination intensity is improved, but device complexity and power consumption increase

Engineering Contradiction:

ImprovebrightnessVSAvoidstructure

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent combines multiple LED chips (blue LED and green LED) into a single integrated light source assembly, eliminating the need for separate high-current lamps. The blue LED and green LED work together to generate cyan light, which is then combined with red light from a separate red LED to produce full-color projection, thereby reducing overall device complexity while maintaining brightness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The light source assembly serves multiple functions: it generates cyan light through blue and green LEDs, combines it with red light for full-color projection, and integrates color separation and combination functions. This multi-functional design replaces traditional separate lamps and optical components, reducing device complexity while achieving sufficient brightness for projection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Illumination intensity

If separate light source lamps are used, then illumination intensity is improved, but power consumption increases

Engineering Contradiction:

ImprovebrightnessVSAvoidpower consumption

Core Design Contradiction:

Illumination intensityVSUse of energy by moving object

Solution Approach 1:

The patent merges blue LED and green LED into a single light source assembly that generates cyan light. This integrated approach reduces total power consumption compared to using separate high-current lamps for each color, as the LEDs operate at lower currents and can be efficiently controlled individually to achieve the required combined brightness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the operational parameters by using multiple low-current LED chips instead of high-current lamps. The blue LED and green LED operate at optimized low currents, and their combined output provides sufficient cyan brightness when integrated with red LED light, thereby reducing overall power consumption while maintaining illumination intensity.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If micro LED chips are transferred to flexible substrates, then adaptability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

ImproveflexibilityVSAvoidtransfer precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent combines multiple micro LED chips (blue LED, green LED) onto a single flexible substrate to form an integrated light source assembly. This merging approach maintains flexibility while distributing the manufacturing precision requirements across multiple smaller chips rather than requiring one large precision transfer, as each micro LED chip can be individually positioned and bonded.

Inventive Principle:

Principle #5Merging (Combining)

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 configuration enables a compact, high-resolution full-color display with improved optical efficiency and simplified manufacturing, reducing performance deterioration and increasing product yield.

Implementation Method 1

the third micro LED panel includes a color conversion film for changing the light of the first or second wavelength to the light of the third wavelength

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Implementation Method 2

a dichroic prism configured to synthesize lights output from the first to third micro LED panels

Methodology Applied

Scientific EffectDichroic reflection: Dichroic Filter

Implementation Method 3

A light emitting diode (LED) is a sort of semiconductor device which converts electric energy to light energy

Methodology Applied

Scientific EffectElectroluminescence: Electroluminescence

Data Source

PatentUS10281812B2Projection device using micro LED panel and method of fabricating the same

Publication Date: 2019.05.07 LUMENS CO LTD

AI summary

Disclosed is a projection device using a micro light emitting diode (LED) panel, the projection device including: a first micro LED panel configured to output light of a first wavelength using first micro LED pixels with the first wavelength; a second micro LED panel configured to output light of a second wavelength using second micro LED pixels with the second wavelength; a third micro LED panel configured to output light of a third wavelength using the first or second micro LED pixels; and a dichroic prism configured to synthesize lights output from the first to third micro LED panels, wherein the third micro LED panel includes a color conversion film for changing the light of the first or second wavelength to the light of the third wavelength.