Micro LED Light Conversion Layout With Reflective Grooves
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Solution Overview
Problem
Existing display devices using micro LEDs face challenges in simultaneously growing red, green, and blue LEDs on a single wafer, leading to inefficiencies in light conversion and increased material consumption.
Innovation Solution
A display device design that increases the thickness of light conversion units and uses reflectors to redirect light emitted by LEDs, minimizing light loss and reabsorption, and optimizing the arrangement of light conversion units within grooves formed by partitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple spin coating processes are used to increase phosphor thickness, then light conversion efficiency is improved, but manufacturing complexity and material consumption increase
Solution Approach 1:
The patent divides the light conversion unit into multiple layers with different phosphor materials. Each layer is optimized for specific wavelength conversion, allowing sufficient phosphor thickness to be achieved without requiring multiple sequential spin coating processes. The segmentation of phosphor types and layers enables improved light conversion efficiency while simplifying the manufacturing process.
2Ease of operation
If black matrix is disposed between LEDs, then light emission directionality is improved, but light loss increases due to absorption
Solution Approach 1:
The patent replaces the black matrix (which absorbs light) with a reflective structure that redirects light. The reflective structure converts the harmful light absorption effect into a beneficial light redirection effect, maintaining directionality while reducing light loss. This resolves the contradiction by transforming the function from light absorption to light reflection.
3Ease of manufacture
If photoresist containing phosphor is applied by spin coating, then light conversion units are formed, but misalignment and distortion occur
Solution Approach 1:
The patent forms the light conversion units by filling grooves or cavities that are pre-formed on the substrate. This preliminary structuring of the substrate provides precise positioning guides for the phosphor material, preventing misalignment and distortion during the filling process. The pre-formed geometric structures ensure accurate placement of light conversion units.
4Productivity
If multiple coating processes are used to form light conversion units, then sufficient phosphor thickness is achieved, but material consumption increases enormously
Solution Approach 1:
The patent concentrates phosphor material in localized regions within grooves or cavities, rather than applying uniform thick layers across the entire surface. This localized concentration achieves sufficient phosphor thickness for effective light conversion while minimizing overall material consumption. The grooves confine the phosphor to specific areas, reducing waste.
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
The proposed solution enhances light conversion efficiency, reduces material consumption, and improves light extraction efficiency by effectively redirecting and converting light emitted by LEDs.
Implementation Method 1
a material including a phosphor is applied to a space between the black matrix to form a plurality of light conversion units
Implementation Method 2
a first reflector between adjacent inorganic light emitting structures and configured to reflect light emitted from the plurality of inorganic light emitting structures
Data Source
AI summary
A display device comprises a first substrate including a plurality of pixels, a plurality of light emitting diodes (LEDs) in each of the plurality of pixels, a plurality of light conversion units on the plurality of LEDs, and a plurality of partitions configured to surround each of the plurality of light conversion units. Each of the plurality of light conversion units is in a groove inside the plurality of partitions.