Micro-LED Protective Layer Curvature for ACF and Optical Space

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Solution Overview

Problem

Current micro-LED display devices face issues with waste of ACF material, limited space for light conversion layers, and poor conductivity due to varying conductive particle sizes in the anisotropic conductive film (ACF) layer, which affects performance.

Innovation Solution

A display device design featuring a protective layer with a curved surface overlapping the optical layer and light shielding element, where the protective layer's elevation is lower than the upper semiconductor layer, allowing for more space for the wavelength conversion layer and improved reflectivity, and includes conductive elements for enhanced conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the protective layer top surface is level with the micro LED, then protection is provided, but ACF material is wasted and space for light conversion layer is limited

Engineering Contradiction:

Improveprotection of micro LEDVSAvoidACF material waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The protective layer top surface is designed with a curved surface that is lower than the micro LED upper surface, rather than being level with it. This curvature allows the protective layer to provide adequate protection while reducing material usage and creating space for the light conversion layer.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If the protective layer top surface is level with the micro LED, then protection is provided, but space for light conversion layer is limited

Engineering Contradiction:

Improveprotection of micro LEDVSAvoidspace for light conversion layer

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The curved surface design of the protective layer creates additional vertical space between the protective layer top surface and the micro LED upper surface, allowing sufficient room for the light conversion layer to be positioned and function effectively.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Quantity of substance

If conductive particles of varying sizes are used in the ACF layer, then conductivity is achieved, but poor conductivity and poor reflectivity result

Engineering Contradiction:

Improveconductive particles in ACF layerVSAvoidconductivity and reflectivity

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent specifies using conductive particles with a controlled size range (0.5-5.0 μm) rather than varying sizes, creating uniform local properties in the ACF layer that improve both conductivity and reflectivity performance.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20260096257A1Electronic device

Publication Date: 2026.04.02 INNOLUX CORP

AI summary

An electronic device is provided. The electronic device includes a substrate, a driving circuit, a diode, an optical layer, a light shielding element and an inorganic layer. The driving circuit is disposed on the substrate. The diode is disposed on the substrate and electrically connected to the driving circuit. The optical layer is disposed on the diode and comprising a first curved surface. The light shielding element is disposed on the substrate and adjacent to the optical layer. The inorganic layer is disposed on the substrate. Moreover, the inorganic layer overlaps the optical layer and the light shielding element. The inorganic layer includes a second curved surface overlapping the first curved surface.