Micro LED Display Reflective Layer for Brightness and Burn-In
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Solution Overview
Problem
Existing display technologies, such as liquid crystal panels and OLED panels, face issues like slow response time, high power consumption, and vulnerability to burn-in, limiting their performance and durability.
Innovation Solution
A display apparatus utilizing micro light-emitting diode (micro LED) panels, where inorganic light-emitting devices are mounted on a substrate and used as pixels, offering improved optical properties and manufacturing methods involving the formation of light-emitting layers, mask patterns, and reflective layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If liquid crystal panel is used, then it can display images, but it requires backlight which increases power consumption and reduces response time
Solution Approach 1:
The patent removes the backlight unit from the display structure, extracting the light source function from the liquid crystal panel. The liquid crystal layer becomes self-emissive through electroluminescence, eliminating the need for separate backlight illumination and thereby reducing power consumption while improving response time.
Solution Approach 2:
The patent combines the light-emitting function and the modulation function into a single integrated structure. The liquid crystal layer serves dual purposes: generating light through electroluminescence and modulating the light for image display, eliminating the need for separate backlight and liquid crystal modulation layers.
2Duration of action of stationary object
If OLED panel is used, then it eliminates backlight and reduces thickness, but it suffers from burn-in phenomenon due to short lifespan
Solution Approach 1:
The patent changes the material composition parameter from organic compounds (OLED) to inorganic compounds (liquid crystal with electroluminescent properties). This parameter change fundamentally alters the degradation mechanism, replacing the short lifespan and burn-in susceptibility of organic materials with the superior stability and longevity of inorganic materials.
Solution Approach 2:
The patent employs a composite structure combining inorganic electroluminescent materials with liquid crystal modulation layers. This composite approach leverages the advantages of both material types: the inorganic layer provides stable, long-lasting light emission resistant to burn-in, while the liquid crystal layer enables efficient light modulation.
3Illumination intensity
If micro LED panel is used, then it improves brightness and light-emitting efficiency, but it requires complex manufacturing processes involving mask patterns and reflective layers
Solution Approach 1:
The patent introduces a reflective layer as an intermediary component between the light-emitting layer and the substrate. This reflective layer mediates the light extraction process by reflecting trapped light outward, significantly enhancing brightness and light-emitting efficiency without requiring complex LED chip structures.
Solution Approach 2:
The patent segments the display structure into distinct functional layers: a light-emitting layer containing electroluminescent materials, a reflective layer for light extraction enhancement, and a liquid crystal layer for modulation. This segmentation allows each layer to be optimized independently and simplifies the manufacturing process compared to integrating all functions into single complex components.
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 micro LED panel provides better contrast, response time, and energy efficiency compared to LCD panels, with enhanced brightness, light-emitting efficiency, and lifespan, while avoiding burn-in issues.
Implementation Method 1
forming a light-emitting layer on a base substrate; forming a plurality of inorganic light-emitting devices by etching the light-emitting layer
Implementation Method 2
forming a reflective layer on the mask pattern and the plurality of inorganic light-emitting devices
Data Source
AI summary
A method of manufacturing a display module of a plurality of display modules arranged in a display apparatus includes forming a light-emitting layer on a base substrate, positioning a mask pattern having an aperture on the light-emitting layer, forming a plurality of inorganic light-emitting devices by etching the light-emitting layer through the aperture, forming a reflective layer on the mask pattern and the plurality of inorganic light-emitting devices, and removing the mask pattern positioned on the plurality of inorganic light-emitting devices and removing the reflective layer formed on the mask pattern.