Dual-Polymer Micro-LED Encapsulation for Durable Clear Vehicle Displays

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Solution Overview

Problem

Existing micro-LED structures lack effective encapsulation methods that provide both structural integrity and optical clarity, particularly in vehicle components such as hoods, decklids, and taillight assemblies, which are subjected to environmental stress and require durable yet transparent displays.

Innovation Solution

A micro-LED encapsulated structure comprising two polymeric layers, where a first polymer layer encapsulates micro-LEDs and interconnections on a supporting layer, and a second polymer layer encapsulates the first layer, with optional reinforcing fibers for added strength, using thermoset or thermoplastic polymers and vitrimers to ensure durability and transparency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single polymer layer is used for encapsulation, then the manufacturing process is simple, but the structural integrity and durability are insufficient

Engineering Contradiction:

Improveencapsulation process simplicityVSAvoidencapsulation durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The encapsulation structure is divided into multiple polymer layers (first polymer layer and second polymer layer), where each layer serves specific functions. The first polymer layer encapsulates the micro-LEDs and interconnections, while the second polymer layer provides additional structural support and environmental protection, thereby improving overall durability without significantly complicating the manufacturing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite polymer structures where different polymer materials are combined in layers. The first polymer layer may use a polymer compatible with micro-LEDs for optimal optical and electrical properties, while the second polymer layer uses a different polymer providing enhanced mechanical strength and environmental resistance, creating a synergistic encapsulation system.

Inventive Principle:

Principle #40Composite materials

2Strength

If reinforcing fibers are added to the polymer matrix, then the structural strength is improved, but the optical transparency may be reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidoptical transparency

Core Design Contradiction:

StrengthVSIllumination intensity

Solution Approach 1:

Reinforcing fibers are strategically placed within the polymer matrix at specific locations where enhanced structural strength is needed, rather than uniformly distributing them throughout. This localized reinforcement approach maintains optical transparency in areas where light transmission is critical while providing structural support where mechanically demanding.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention employs fibers with optimized optical properties, including transparent or translucent fiber materials that minimize light absorption and scattering. The fiber composition and arrangement are designed to maintain the desired optical appearance and light transmission characteristics while providing the necessary structural reinforcement.

Inventive Principle:

Principle #32Color changes

Data Source

PatentUS12604577B2Micro-LED encapsulated structure including two polymeric layers

Publication Date: 2026.04.14 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A micro-LED encapsulated structure comprising a plurality of micro-LEDs and interconnections arranged on a supporting layer. A first polymer layer includes a first polymer matrix encapsulating the plurality of micro-LEDs, the interconnections, and the supporting layer. A second polymer layer includes a second polymer matrix encapsulating at least one side of the first polymer layer.