Micro LED Wavelength Conversion Module for Blue Light Leakage
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Solution Overview
Problem
Existing micro LED display technologies face issues with low light conversion efficiency and blue light leakage, resulting in insufficient color purity due to incomplete absorption of excitation light beams.
Innovation Solution
A light source device comprising a micro light-emitting element layer, a transparent substrate, and a wavelength conversion module with specific layers and structures that include reflection and light cut-off layers to recycle and convert light beams efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single color light micro LED element array is used to excite wavelength conversion materials, then the device structure is simplified, but the light conversion efficiency is low and color purity is insufficient due to blue light leakage
Solution Approach 1:
The wavelength conversion module is divided into multiple wavelength conversion layers with different conversion functions, arranged in sequence from the micro LED light-emitting surface toward the transparent substrate. Each layer converts specific wavelength ranges, enabling staged conversion of excitation light to reduce blue light leakage and improve color purity while maintaining efficient light utilization
Solution Approach 2:
Reflection layers are introduced on the sidewalls of the wavelength conversion layers to create a three-dimensional light management structure. These reflection layers redirect oblique incident excitation light that would otherwise be lost, directing it back into the wavelength conversion layers for additional conversion opportunities, thereby improving overall light conversion efficiency
2Illumination intensity
If wavelength conversion materials are used to form various color lights, then color saturation is improved, but blue light leakage occurs resulting in insufficient color purity
Solution Approach 1:
The wavelength conversion module is divided into multiple wavelength conversion layers with different conversion functions, arranged in sequence from the micro LED light-emitting surface toward the transparent substrate. Each layer converts specific wavelength ranges, enabling staged conversion of excitation light to reduce blue light leakage and improve color purity while maintaining efficient light utilization
Solution Approach 2:
The multi-layer wavelength conversion structure ensures continuous conversion of excitation light across different wavelength ranges. By arranging layers with complementary conversion characteristics in sequence, the system achieves sustained and complete wavelength transformation, minimizing unconverted blue light that would compromise color purity
3Loss of energy
If multiple wavelength conversion layers are arranged in sequence, then light conversion efficiency is improved, but the manufacturing process becomes more complex
Solution Approach 1:
Multiple wavelength conversion layers, reflection layers, and barrier structures are integrated into a unified wavelength conversion module that is pre-assembled and then bonded as a single unit to the micro LED light-emitting element array. This merging approach simplifies the overall manufacturing process by reducing the number of separate bonding steps while maintaining the complex multi-layer structure necessary for high light conversion efficiency
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
Improves optical and conversion efficiencies, reduces light loss, and enables miniaturization by allowing for precise manufacturing with a single bonding process.
Implementation Method 1
The reflection layers are located between the barrier structures and any one of a sidewall of the first wavelength conversion layer, a sidewall of the second wavelength conversion layer, and a sidewall of the light transmission layer in the arrangement direction
Implementation Method 2
a technology plan that utilizes a single color light (e.g., as blue light) micro LED element array to excite wavelength conversion materials (e.g., nano-scale phosphors or quantum dot materials) to form the required various color lights
Implementation Method 3
The light cut-off layer is in contact with the first surface of the transparent substrate, in which the light cut-off layer is in contact with and overlaps the first wavelength conversion layer and the second wavelength conversion layer
Data Source
AI summary
A light source device and a manufacturing method of the light source device is provided. The light source device includes a micro light-emitting element layer, a transparent substrate and a wavelength conversion module. The wavelength conversion module includes a first wavelength conversion layer, a second wavelength conversion layer, a light transmission layer, multiple barrier structures, multiple reflection layers and a light cut-off layer. The first wavelength conversion layer, the second wavelength conversion layer, and the light transmission layer are arranged in an arrangement direction. Any two of the first wavelength conversion layer, the second wavelength conversion layer, and the light transmission layer are separated from each other by one of the barrier structures. The reflection layers are located between the barrier structures and any one of a sidewall of the first wavelength conversion layer, a sidewall of the second wavelength conversion layer, and a sidewall of the light transmission layer.