Micro-LED Lamination Between Flexible and Rigid Substrates
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Solution Overview
Problem
Current micro-LED display technologies face challenges in improving efficiency and brightness while maintaining optical properties of the surface on which LEDs are mounted, especially when dealing with curved or irregularly shaped substrates, and require additional protection layers.
Innovation Solution
A sparse array of LEDs is assembled on a transparent flexible substrate, which is then laminated onto a substrate with desired optical properties, using an adhesive layer that encapsulates the LEDs and provides protection, allowing for application on non-flat surfaces without additional cover layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro-LEDs are mounted on a rigid flat substrate, then manufacturing precision is improved, but adaptability to curved or irregular surfaces deteriorates
Solution Approach 1:
The substrate system is segmented into two functional layers: a rigid flat substrate for LED assembly and a flexible substrate for conformal mounting. This segmentation allows each layer to perform its specialized function - the rigid substrate provides manufacturing precision while the flexible substrate provides adaptability to curved surfaces.
Solution Approach 2:
A flexible substrate acts as an intermediary between the rigid LED assembly substrate and the curved target surface. This intermediary layer can be conformally mounted to irregular surfaces while carrying the rigid substrate with LEDs, thereby enabling adaptability without compromising manufacturing precision.
2Reliability
If additional protection layers are added to protect LEDs, then reliability is improved, but device complexity increases
Solution Approach 1:
The flexible substrate serves multiple functions simultaneously: it acts as a structural support for the rigid substrate, provides conformal mounting capability, and functions as a protection layer for the LEDs. By merging these functions into a single component, device complexity is reduced while maintaining reliability.
Solution Approach 2:
The flexible substrate is designed as a multi-functional component that provides mechanical support, environmental protection, and surface conformality. This universal component eliminates the need for separate protection layers, thereby reducing device complexity while improving reliability through comprehensive protection.
3Illumination intensity
If transparent flexible substrate is used, then optical properties are maintained, but manufacturing complexity increases
Solution Approach 1:
The substrate system is divided into rigid and flexible components, each optimized for specific requirements. The transparent flexible substrate is specifically designed to maintain optical properties while the rigid substrate handles manufacturing, simplifying the overall manufacturing process despite the dual-substrate structure.
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 enhances the efficiency and brightness of micro-LED displays by maintaining the optical properties of the surface, providing protection to the LEDs, and enabling their application on curved or irregularly shaped substrates without the need for additional protection layers.
Implementation Method 1
a rigid substrate adhered to the transparent flexible substrate with an adhesive layer such that the sparse array of LEDs is located between the rigid substrate and the transparent flexible substrate
Data Source
AI summary
A light source can include a transparent flexible substrate. A sparse array of light-emitting diodes (LEDs) can be disposed on the transparent flexible substrate. A rigid substrate can be adhered to the transparent flexible substrate such that the sparse array of LEDs is located between the rigid substrate and the transparent flexible substrate. The rigid substrate can be adhered to the transparent flexible substrate with an adhesive layer. The sparse array of LEDs can be encapsulated in an adhesive of the adhesive layer. The adhesive can have a refractive index that is between a refractive index of the transparent flexible substrate and a refractive index of the rigid substrate, inclusive. The sparse array of LEDs can have a light-emitting area that is less than or equal to a specified fraction of a surface area of the sparse array, such as 5 percent or 1 percent.