Micro-LED Microlens Self-Alignment for Front-View Light Efficiency
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Solution Overview
Problem
Micro-LED displays face challenges with low light efficiency at the front view angle and high power consumption due to inherent light patterns and insufficient alignment precision of microlenses, leading to nonuniform display performance.
Innovation Solution
A display panel design featuring a circuit substrate with light-emitting components having distinct hydrophilic and hydrophobic surfaces, where microlenses are automatically aligned based on these surface properties, ensuring precise positioning and improved light focusing, thereby enhancing light emission at the front view angle and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If microlenses are used to focus light from micro-LEDs, then light efficiency at front view angle is improved, but alignment precision between microlenses and light-emitting surfaces is insufficient leading to nonuniform display performance
Solution Approach 1:
The light-emitting component is equipped with hydrophilic and hydrophobic surfaces that automatically guide microlens material to the correct position. The microlens self-aligns with the light-emitting surface through wetting behavior differences, eliminating the need for external alignment mechanisms and achieving precise positioning.
Solution Approach 2:
The invention changes the surface energy parameters of the light-emitting component by creating regions with different hydrophilicity. This parameter change enables the microlens material to differentiate between the light-emitting surface and surrounding areas, achieving precise alignment through material property modification rather than mechanical positioning.
2Manufacturing precision
If microlenses are precisely aligned with light-emitting surfaces, then light focusing is optimized, but device complexity increases due to additional alignment mechanisms
Solution Approach 1:
The light-emitting component's surface is modified with hydrophilic and hydrophobic regions that automatically guide microlens positioning. This self-aligning mechanism eliminates the need for external alignment tools, fixtures, or complex positioning systems, reducing device complexity while achieving precise alignment.
Solution Approach 2:
The invention replaces mechanical alignment systems with a chemical/wetting-based alignment mechanism. The hydrophilic-hydrophobic surface pattern substitutes for mechanical positioning devices, achieving precise microlens alignment through surface energy differences rather than mechanical constraints.
3Illumination intensity
If microlenses are precisely positioned on light-emitting surfaces, then light emission uniformity is improved, but manufacturing process complexity increases
Solution Approach 1:
The light-emitting component automatically positions the microlens through its hydrophilic-hydrophobic surface pattern. The microlens material self-assembles at the correct location based on wetting behavior, eliminating the need for complex external positioning equipment and simplifying the manufacturing process.
Solution Approach 2:
The hydrophilic-hydrophobic surface pattern acts as an intermediary that mediates between the microlens material and the light-emitting surface. This intermediate surface property layer guides the microlens to the correct position without requiring direct mechanical intervention or complex positioning systems.
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
The solution enhances light emission uniformity and reduces power consumption by ensuring accurate microlens alignment and optimized light focusing, addressing the limitations of existing micro-LED display technologies.
Implementation Method 1
The multiple microlenses are located on a side of the multiple light-emitting components facing away from the circuit substrate
Implementation Method 2
One of the first surface or the second surface is a hydrophilic surface. The other of the first surface or the second surface is a hydrophobic surface
Data Source
AI summary
A display panel includes a circuit substrate, multiple light-emitting components located on a side of the circuit substrate, and multiple microlenses. Each light-emitting component includes a first surface facing away from the circuit substrate and also includes a second surface at least partially surrounds the first surface. One of the first surface or the second surface is a hydrophilic surface, and the other is a hydrophobic surface. The multiple microlenses are located on a side of the multiple light-emitting components facing away from the circuit substrate. The orthographic projection of the microlens on the plane where the circuit substrate is located overlaps the orthographic projection of the first surface on the plane where the circuit substrate is located and does not overlap the orthographic projection of the second surface on the plane where the circuit substrate is located.