Micro-LED Black Matrix Coating Without Pattern Etching
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Solution Overview
Problem
Existing micro-LED display technologies face inefficiencies in manufacturing black matrix structures due to the wasteful and costly process of pattern-wise etching, which increases material loss and production costs while reducing ambient light reflection and contrast.
Innovation Solution
The implementation of unpatterned deposition and etching of light-absorbing materials, where a uniform blanket coating of light-absorbing material is applied and cured without pattern-wise etching, allowing components to protrude from the layer, thus reducing material usage and manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If pattern-wise etching is used to construct black matrix structures, then ambient light reflection is reduced and display contrast is improved, but material waste increases and manufacturing costs increase
Solution Approach 1:
The patent extracts the black matrix material only where needed by using a sacrificial layer approach. The black matrix material is deposited as a continuous layer, then portions corresponding to pixel regions are removed by etching through the sacrificial layer, leaving black matrix only in the inter-pixel regions. This eliminates material waste by not depositing black matrix material over the entire substrate beforehand.
Solution Approach 2:
The patent applies preliminary action by first depositing a sacrificial layer and defining pixel regions before depositing the black matrix material. This preliminary structuring allows the black matrix to be selectively formed only where needed, preventing material waste from the start rather than removing excess material afterward.
2Object-affected harmful factors
If pattern-wise etching is used to construct black matrix structures, then ambient light reflection is reduced and display contrast is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the black matrix formation process with the pixel electrode formation process by using the same sacrificial layer removal step for both. The sacrificial layer serves dual purposes: defining pixel regions and enabling selective black matrix formation, thereby reducing overall process complexity.
Solution Approach 2:
The sacrificial layer serves multiple functions: it defines pixel regions, acts as a mask for black matrix deposition, and is later removed to expose pixel electrodes. This multi-functionality reduces the number of separate process steps needed, simplifying the overall manufacturing process.
3Ease of manufacture
If unpatterned deposition of light-absorbing material is used, then manufacturing process is simplified and material waste is reduced, but light emission from pixels may be occluded
Solution Approach 1:
The patent extracts the black matrix material from regions where it would occlude light emission by using the sacrificial layer removal process. After unpatterned deposition of black matrix material over the entire substrate, the sacrificial layer is removed, and the black matrix material in pixel regions is simultaneously removed, leaving only inter-pixel black matrix that absorbs ambient light without blocking pixel light emission.
Solution Approach 2:
The patent uses preliminary action by removing the sacrificial layer before finalizing the black matrix structure. This preliminary removal creates openings in the black matrix layer at pixel locations, ensuring that light emission paths are cleared before the black matrix is fully cured or finalized, preventing occlusion of pixel light.
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 method reduces material waste, simplifies the manufacturing process, and enhances the display's ability to absorb ambient light without occluding light emitters, thereby improving contrast and reducing production costs.
Implementation Method 1
a 'black matrix' is typically provided over the display and between the display pixels to absorb the ambient light without occluding light emitted from the display pixels
Implementation Method 2
uniformly blanket coating the display surface with a curable layer of uncured light-absorbing material... and curing the curable layer of uncured light-absorbing material to provide a layer of cured light-absorbing material
Data Source
AI summary
A method of making a display structure comprises providing a display substrate having a display surface, disposing components on and in contact with the display surface, uniformly blanket coating the display surface with a curable layer of uncured light-absorbing material, and curing the curable layer of uncured light-absorbing material to provide a layer of cured light-absorbing material so that the components project from the layer of cured light-absorbing material without having pattern-wise etched the layer of cured light-absorbing material after the light-absorbing material has been cured. The uniform blanket coating has a thickness greater than a thickness of the component, disposing the components comprises printing the components through the uniform blanket coating such that the components protrude from the uniform blanket coating, or the component is coated with a de-wetting material.