Micro-transfer Printed LED Color Filter Structure
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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 color conversion materials like phosphors and quantum dots, and they often suffer from manufacturing inefficiencies and uniformity issues in producing a wide range of colors.
Innovation Solution
The development of micro-transfer printed color-filter structures that integrate a color filter and a fractured tether, using materials such as curable resin, dyes, pigments, semiconductor crystals, phosphors, or quantum dots, which are efficiently manufactured and applied to LEDs to filter or convert light, reducing material usage and processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If color conversion materials like phosphors and quantum dots are used to produce colored light, then color gamut can be improved, but manufacturing cost and material expense increase significantly
Solution Approach 1:
The patent divides the color filter structure into multiple discrete layers (first color filter layer, second color filter layer, third color filter layer) with different functions. Each layer is deposited separately and can be optimized independently, allowing the use of cheaper materials in non-critical layers while maintaining overall color performance.
Solution Approach 2:
Different regions of the display have different color filter requirements. The patent applies color conversion materials selectively in specific areas where they are most needed for color gamut enhancement, rather than uniformly across the entire display, reducing overall material usage and cost.
2Reliability
If traditional color filter manufacturing methods are used, then color filtering performance can be achieved, but manufacturing efficiency is low and production time is long
Solution Approach 1:
The patent pre-patterns the color filter layers on a source substrate before transferring them to the final display substrate. This allows for batch processing and quality control to be performed on the source substrate, improving manufacturing efficiency while maintaining color filtering performance.
Solution Approach 2:
The patent introduces a source substrate as an intermediary carrier for the color filter layers. This intermediate substrate enables separate fabrication and testing of color filters before final assembly, decoupling the manufacturing processes and improving overall production efficiency.
3Adaptability or versatility
If color filters are manufactured separately and then assembled with LEDs, then manufacturing flexibility is maintained, but assembly complexity and processing steps increase
Solution Approach 1:
The patent combines multiple color filter layers and the LED array into a single integrated structure on the source substrate. This merging of components reduces the number of separate assembly steps required and simplifies the final manufacturing process while maintaining the flexibility to adjust individual layer properties.
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 significantly reduces the cost and material usage of color filters, enhances manufacturing efficiency, and improves color uniformity by integrating color filters directly with LEDs through micro-transfer printing, resulting in more cost-effective and robust light-emitting displays with improved color gamut.
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
Phosphors are often used as color-conversion materials. For example, U.S. Patent No. 8,450,927 describes an LED lamp using a phosphor
Implementation Method 3
a single kind of light emitter is used to optically stimulate (pump) a second light emitter with light having a first energy (frequency). The second light emitter absorbs the first light and then emits second light having a lower energy (frequency)
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A micro-transfer printed intermediate structure comprises an intermediate substrate and one or more pixel structures disposed on the intermediate substrate. Each pixel structure includes an LED, a color filter, and a fractured pixel tether physically attached to the pixel structure. A fractured intermediate tether is physically attached to the intermediate substrate. A method of making an intermediate structure source wafer comprises providing a source wafer having a patterned sacrificial layer including sacrificial portions separated by anchors, disposing an intermediate substrate over the patterned sacrificial layer, and disposing one or more pixel structures on the intermediate substrate entirely on or over each sacrificial portion. Each pixel structure includes an LED, a color filter, and a fractured pixel tether physically attached to the pixel structure to form an intermediate structure.