Micro-lens Array with Integrated Color Converter for Micro-LED Displays
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Solution Overview
Problem
Current technologies face challenges in efficiently transferring and assembling a large number of micro LEDs required for high-resolution micro LED displays, leading to prolonged process times and difficulties in achieving precise bonding.
Innovation Solution
A micro-lens array with a color-conversion function is integrated into the micro-LED display module, featuring a body with bank portions, lens parts, barrier ribs, and a color converter that converts light emitted from micro LEDs, allowing for RGB display without separate color-conversion films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate color-conversion films are used for each micro LED, then color accuracy is improved, but device complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent combines multiple color-conversion films (red, green, blue converters) into a single integrated color-conversion layer structure. Each micro LED column is associated with a composite color-conversion layer that contains multiple converter materials, eliminating the need for separate assembly steps for each color film and significantly reducing manufacturing complexity while maintaining color accuracy
Solution Approach 2:
The color-conversion layer is designed to perform multiple functions simultaneously: it converts blue light to red, green, and blue wavelengths, acts as a wavelength multiplexer, and provides color filtering all in a single structural element. This multi-functional design simplifies the overall device architecture while achieving precise color reproduction
2Loss of energy
If a wavelength multiplexer is added to improve light extraction efficiency, then optical efficiency is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The wavelength multiplexer function is merged with the color-conversion layer rather than being implemented as a separate component. The same layered structure that converts wavelengths also serves as the multiplexer, combining color conversion and light extraction enhancement functions in a single integrated element
Solution Approach 2:
The color-conversion layer simultaneously performs wavelength conversion, light extraction, and optical guiding functions. This multi-functional design eliminates the need for additional dedicated wavelength multiplexer components, reducing structural complexity while improving optical efficiency
3Manufacturing precision
If precise bonding of multiple color-conversion films is performed, then color uniformity is improved, but manufacturing time and process complexity increase
Solution Approach 1:
Multiple color-conversion films are pre-assembled and pre-aligned into a single integrated color-conversion layer structure before being transferred to the final device position. This preliminary assembly ensures precise color alignment is achieved once, during the pre-assembly stage, rather than requiring precise bonding at the final assembly stage
Solution Approach 2:
The patent merges multiple separate color-conversion film assembly operations into a single integrated assembly process. By combining red, green, and blue converter layers into one composite structure, the number of precise bonding operations is reduced from multiple separate steps to a single assembly operation
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 solution enables the display of color images using a single blue micro LED, reducing assembly time and manufacturing costs, while improving optical efficiency by eliminating light loss through the color-conversion film and minimizing thermal deformation-related peeling issues.
Implementation Method 1
a lens part (11) protruding on an opposite surface (a top surface) of the micro-lens array in one-to-one correspondence to each of the micro-LEDs
Implementation Method 2
extracting total internally reflected light to an upper surface
Implementation Method 3
a color converter (20) provided in a bank portion (12) and converting a color of light emitted from each of the plurality of micro-LEDs
Data Source
AI summary
The present invention relates to a micro-lens array having a color-conversion function and provided in a micro-LED display module, a micro-LED display module including the micro-lens array, and a method for manufacturing the micro-lens array, An micro-lens array according to an embodiment of the present invention is provided in a micro-LED display module in which micro-LEDs themselves are used as light-emitting materials. The micro-lens array may comprise: a body; bank parts formed to be recessed inward from one surface of the body so as to be in one-to-one correspondence with the micro-LEDs, respectively; lens parts formed to protrude from the opposite surface of the body so as to be in one-to-one correspondence with the bank parts, respectively; a partition wall part formed between the bank parts; and a color-conversion part provided in each of the bank parts so as to convert the color of light emitted from each of the micro-LEDs.