Micro-LED Reflective Cup Structure for Brightness and Crosstalk

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Solution Overview

Problem

Micro-LED display systems face challenges in balancing pixel resolution and brightness due to large divergence angles of light emission, leading to reduced efficiency, inter-pixel light crosstalk, and loss of contrast.

Innovation Solution

The implementation of LED chip structures with cup-like reflective elements and isolation layers that surround LED pixels, utilizing oblique light angles and reducing divergence, thereby enhancing light collection and directionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If micro-LED pixel size is reduced to improve resolution, then resolution increases, but brightness decreases due to smaller light-emitting area

Engineering Contradiction:

Improvepixel resolutionVSAvoidbrightness

Core Design Contradiction:

Measurement precisionVSIllumination intensity

Solution Approach 1:

The patent introduces a vertical reflective structure (cup-like shape) around the micro-LED pixel to redirect oblique light rays that would otherwise be lost. This three-dimensional light management approach captures light from multiple angles and redirects it vertically, effectively increasing brightness without increasing pixel area, thus resolving the contradiction between high resolution and high brightness

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent converts the harmful effect of large divergence angles and oblique light emission (which causes light loss and crosstalk) into a beneficial effect by using the reflective cup structure to redirect these oblique rays into useful vertical light output, thereby improving brightness and reducing crosstalk simultaneously

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Ease of manufacture

If conventional light management structures are used, then manufacturing is simpler, but light utilization efficiency is low due to unutilized oblique light angles

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidlight utilization efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The reflective cup structure is self-forming through standard semiconductor fabrication processes (etching, depositing, planarization), requiring no additional complex manufacturing steps. The structure automatically captures and redirects oblique light rays, making the system self-optimizing for light efficiency without increasing manufacturing complexity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The reflective cup structure serves multiple functions simultaneously: it acts as a light reflector, a sidewall protection layer, and a crosstalk barrier. This multi-functionality improves light efficiency without requiring separate structures for each function, maintaining manufacturing simplicity

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If no isolation structures are used, then device complexity is lower, but inter-pixel crosstalk increases due to large divergence angles

Engineering Contradiction:

Improvestructure complexityVSAvoidinter-pixel crosstalk

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The reflective cup structure is formed around each individual micro-LED pixel, creating isolated light management zones for each pixel. This segmentation prevents light from one pixel from interfering with adjacent pixels, effectively reducing crosstalk while maintaining a relatively simple overall device structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reflective cup structure acts as an intermediary element between adjacent pixels, blocking and redirecting oblique light rays before they can cause crosstalk. This intermediary structure reduces crosstalk without requiring direct modification of the pixel elements themselves

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 approach improves brightness, contrast, and power efficiency, reducing inter-pixel crosstalk and enhancing image quality while minimizing power consumption.

Implementation Method 1

a reflective layer disposed directly or indirectly on the upper isolation part

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS11804582B2Light-emitting diode chip structures with reflective elements

Publication Date: 2023.10.31 JADE BIRD DISPLAY (SHANGHAI) LTD

AI summary

A light-emitting diode (LED) chip structure with a cup-like reflective element is provided. The LED chip structure comprises a substrate, an isolation element and a mesa including an LED surrounded by the isolation element. The isolation element comprises an upper isolation part and a lower isolation part. The lower isolation part is positioned in the substrate and the upper isolation part protrudes from a surface of the substrate. A reflective layer is disposed on a sidewall of the upper isolation part, and a bottom of the reflective layer does not contact the mesa. The cup-like reflective element at least includes the isolation element with the reflective layer.