Micro-Transfer Color Filter Integration for Display Uniformity
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Solution Overview
Problem
Current methods for producing colored light in displays are inefficient and costly due to the use of expensive materials like phosphors and quantum dots, and they often suffer from manufacturing inefficiencies and performance uniformity issues.
Innovation Solution
The development of micro-transfer printed color-filter structures that integrate color filters and LEDs, using materials such as curable resins, dyes, pigments, and semiconductor crystals, to efficiently filter or convert light, reducing material usage and patterning steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If color filters and LEDs are integrated using micro-transfer printing, then manufacturing efficiency and color uniformity are improved, but device structure and fabrication process become more complex
Solution Approach 1:
The fabrication process is divided into separate stages: first forming LEDs on an LED substrate, then forming color filters on a separate color-filter substrate, and finally transferring the color-filter substrate to the LED substrate. This segmentation allows each component to be optimized independently while achieving high color uniformity through precise alignment and transfer processes.
2Adaptability or versatility
If conventional color conversion materials like phosphors and quantum dots are used, then color gamut can be achieved, but material cost and manufacturing complexity increase
Solution Approach 1:
The patent replaces expensive color conversion materials like phosphors and quantum dots with organic dyes and pigments embedded in curable resin. These alternative materials are significantly cheaper while still providing the required color gamut when excited by LEDs, thereby reducing material costs without sacrificing color performance.
3Ease of operation
If white-light emitters with color filters are used, then colored light can be produced, but light efficiency is reduced due to wasted white light
Solution Approach 1:
The patent changes the operational parameters by using LEDs that emit specific wavelengths (blue, green, red) directly, rather than using white-light emitters. This wavelength-specific emission reduces energy waste because the LED emission spectrum closely matches the absorption spectrum of the corresponding color filter, minimizing lost light and improving overall 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
This approach reduces material costs and improves manufacturing efficiency, achieving improved color gamut and uniformity in displays by integrating color filters and LEDs in a robust and simplified structure.
Implementation Method 1
A structure that filters light by absorbing at least a portion of some of the frequencies of the light and transmitting at least a portion of some of the frequencies of the light
Implementation Method 2
Color filters, pigments, phosphors, and quantum dots
Implementation Method 3
A structure that changes the frequency of at least some of the light by absorbing and at least a portion of some of the frequencies of the light and emitting light of a different frequency and of a lower energy
Implementation Method 4
Phosphors are often used as color-conversion materials
Implementation Method 5
Another technique used to provide colored light is color conversion, in which a single kind of light emitter is used to optically stimulate (pump) a second light emitter
Data Source
AI summary
A micro-transfer color-filter device comprises a color filter, an electrical conductor disposed in contact with the color filter, and at least a portion of a color-filter tether attached to the color filter or structures formed in contact with the color filter. In certain embodiments, a color filter is a variable color filter electrically controlled through one or more electrodes and can be responsive to heat, electrical current, or an electrical field to modify its optical properties, such as color, transparency, absorption, or reflection. In certain embodiments, A color-filter device includes connection posts and can be provided in or on a source wafer suitable for micro-transfer printing. In some embodiments, a color-filter device is disposed on a device substrate and can include a control circuit for controlling the color filter. An array of micro-transfer color-filter devices can be disposed on a display substrate in order to form a display.