Micro-LED Isolation Walls for UV Crosstalk Blocking
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Solution Overview
Problem
The integration of micro-LEDs with different color emissions into a single panel is challenging due to stringent placement accuracy requirements, which limits throughput and yield, and existing opaque materials do not effectively block UV light, leading to emission crosstalk and color mixing.
Innovation Solution
A method for manufacturing micro-LED displays involves depositing an opaque material over micro-LEDs to form isolation walls that extend vertically above the micro-LEDs, effectively blocking UV light and preventing crosstalk between subpixels. This process includes depositing a first material to cover the micro-LEDs, removing portions to form trenches, and depositing a second opaque material to fill these trenches and create isolation walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pick-and-place step is used to transfer micro-LED devices from donor substrates to destination substrate, then integration of multiple colors is achieved, but placement accuracy requirements limit throughput and yield
Solution Approach 1:
The patent merges the micro-LED fabrication process with the color conversion layer deposition process into a single integrated flow. Multiple colors are achieved by selectively depositing different color conversion materials (quantum dots, fluorescent materials) at specific pixel locations on monochrome micro-LED substrates, eliminating the need for separate pick-and-place steps for different colored micro-LEDs.
Solution Approach 2:
The patent performs preliminary fabrication of monochrome micro-LEDs on donor substrates with all necessary structural layers already in place. The substrates are prepared with contact holes, conductive layers, and insulation layers before color conversion material deposition, enabling direct transfer and integration without requiring post-fabrication modifications or separate assembly steps.
2Object-affected harmful factors
If existing opaque materials are used between subpixels, then some light blocking is achieved, but UV light is not effectively blocked leading to emission crosstalk and color mixing
Solution Approach 1:
The patent changes the optical parameters of the isolation material by selecting materials with high absorption coefficients specifically for UV wavelengths. The isolation material is chosen to have strong UV absorption capability while maintaining appropriate visibility characteristics, effectively blocking UV light from adjacent subpixels without significantly affecting visible light transmission.
Solution Approach 2:
The patent employs composite material structures where the isolation material may be combined with other functional layers. The isolation material works in conjunction with the color conversion layers and substrate structures to achieve comprehensive UV blocking and crosstalk prevention while maintaining display performance.
3Productivity
If color conversion agents are selectively deposited at specific pixel locations on monochrome micro-LEDs, then pick-and-place step is bypassed, but UV light crosstalk between adjacent subpixels occurs
Solution Approach 1:
The patent extracts the harmful UV light propagation path by introducing isolation material between adjacent subpixels. This isolation material specifically targets and blocks UV wavelengths, preventing UV crosstalk while allowing the color conversion process to proceed effectively. The isolation structures are strategically placed to intercept UV light before it can stimulate adjacent subpixels.
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 use of opaque isolation walls significantly reduces light losses, color crosstalk, and color conversion layer deposition accuracy issues, thereby improving display brightness and color gamut while maintaining color purity.
Implementation Method 1
The second material is an opaque material... effectively blocking UV light and preventing crosstalk between subpixels
Data Source
AI summary
A display screen includes a backplane, an array of light-emitting diodes electrically integrated with the backplane, the array of light-emitting diodes configured to emit UV light in a first wavelength range, and a plurality of isolation walls formed on the backplane between adjacent light-emitting diodes of the array of light-emitting diodes with the isolation walls spaced apart from the light-emitting diodes and extending above the light-emitting diodes. The plurality of isolation walls include a core of a first material and a coating covering at least a portion of the core extending above the light-emitting diodes. The coating is an opaque second material having transmittance less than 1% of light in the first wavelength range.