Micro-LED Display Assembly with Color Conversion Isolation Walls
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The fabrication of micro-LED displays faces challenges in integrating multiple colors onto a single panel due to stringent placement accuracy requirements and the need for separate processes for different color micro-LEDs, which limits throughput and yield, and existing color conversion methods suffer from alignment accuracy, scalability, and resolution issues.
Innovation Solution
A method involving the selective deposition of photo-curable fluids containing color conversion agents over monochrome micro-LEDs, where the LEDs are activated to cure and form color conversion layers, allowing for precise and high-throughput formation of multi-color displays without the need for pick-and-place steps, using techniques like inkjet or aerosol jet printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate fabrication processes are used for different color micro-LEDs, then color diversity is achieved, but manufacturing complexity and process time increase
Solution Approach 1:
The patent segments the color conversion function into separate photo-curable fluid layers, each containing specific color conversion agents. This allows monochrome micro-LEDs to be converted into multi-color displays through selective deposition and curing of these segmented layers, avoiding the need to fabricate different colored micro-LEDs separately.
Solution Approach 2:
The patent introduces photo-curable fluids containing color conversion agents as an intermediary between the monochrome micro-LEDs and the final multi-color display. These fluids act as mediators that convert the single-color light from micro-LEDs into multiple colors through photopolymerization and color conversion, simplifying the manufacturing process.
2Adaptability or versatility
If pick-and-place steps are used to transfer micro-LEDs, then integration of multiple colors is achieved, but placement accuracy requirements limit throughput and yield
Solution Approach 1:
The patent merges all micro-LEDs of the same color onto a single substrate before applying color conversion layers. This eliminates the need for pick-and-place operations to integrate different colored micro-LEDs, as the color differentiation is achieved through the photo-curable fluid layers rather than physical assembly of differently colored LEDs.
Solution Approach 2:
The patent replaces the mechanical pick-and-place system with a photopolymerization-based color conversion system. Instead of mechanically transferring micro-LEDs to their correct positions, the system uses light-activated chemical reactions to assign colors to specific micro-LED locations, dramatically improving throughput and eliminating placement accuracy constraints.
3Manufacturing precision
If high-resolution shadow masks or inkjet printing are used for selective deposition, then alignment accuracy is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses periodic activation of light sources to cure photo-curable fluids in a sequential manner. By controlling which micro-LEDs are activated at each stage, the system achieves precise spatial selection without requiring complex shadow masks or inkjet printing systems, simplifying the deposition apparatus while maintaining alignment accuracy.
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 enables the fabrication of multi-color micro-LED displays with improved yield and throughput, allowing for large format and flexible displays, while ensuring alignment accuracy and reducing the complexity of the manufacturing process.
Implementation Method 1
activating a first plurality of light emitting diodes in the array of light emitting diodes to illuminate and cure the first photo-curable fluid
Implementation Method 2
The monochrome LEDs can generate relatively short wavelength light, e.g., purple or blue light, and the color conversion agents can convert this short wavelength light into longer wavelength light, e.g., red or green light for red or green pixels
Data Source
AI summary
A multi-color display includes a backplane having backplane circuitry, an array of micro-LEDs electrically integrated with backplane circuitry of the backplane, a color conversion layer over each of a plurality of light emitting diodes, and a plurality of isolation walls separating adjacent micro-LEDs of the array.