Micro-LED Phosphor Coatings That Resist Lamination Deformation
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Solution Overview
Problem
Phosphor deformation during the lamination process of micro-LED displays leads to unpredictable color shifting, affecting the quality and consistency of the display's color output.
Innovation Solution
A protective layer is patterned around the micro-LED layer to maintain phosphor shape during lamination, and a color-shifting coating is used to convert the emitted color of the LEDs, with the protective layer optionally dyed to match the color of the coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If phosphor coating is applied during the lamination process, then color conversion is achieved, but phosphor deformation occurs causing unpredictable color shifting
Solution Approach 1:
The phosphor coating is applied to the micro-LEDs before the lamination process, and a protective layer is formed over the phosphor coating prior to lamination. This preliminary protection prevents the phosphor from deforming during the subsequent high-pressure lamination process, thereby maintaining color consistency while still achieving color conversion.
Solution Approach 2:
A protective layer is introduced as an intermediary between the phosphor coating and the lamination pressure. This protective layer absorbs or distributes the mechanical stress during lamination, preventing direct deformation of the phosphor particles while allowing the lamination to proceed for sealing and structural integrity.
2Strength
If high pressure is applied during lamination to seal the display, then structural integrity is improved, but phosphor deformation increases causing color shifting
Solution Approach 1:
The protective layer is applied beforehand to cushion and protect the phosphor coating during the high-pressure lamination process. This preliminary protective measure allows the necessary pressure to be applied for structural integrity while preventing the phosphor from deforming and causing color shifts.
3Adaptability or versatility
If phosphor is deformed during lamination, then color shifting occurs, but this leads to unpredictable color output requiring additional quality control
Solution Approach 1:
By applying the protective layer before lamination, the phosphor coating is pre-protected from deformation. This ensures that the phosphor maintains its original shape and color properties throughout the manufacturing process, leading to predictable and accurate color output while preserving the desired color gamut.
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 prevents phosphor deformation, ensuring consistent and accurate color emission across the micro-LED display, with the ability to achieve a wider color gamut and more uniform color output.
Implementation Method 1
The color-shifting coating can include at least one of red phosphors, yellow phosphors, and green phosphors
Data Source
AI summary
Aspects of the disclosure include light-emitting diodes (LEDs) formed without phosphor deformation during the lamination process. An exemplary method can include forming one or more LEDs on a backplane and forming a protective layer on the backplane. The protective layer can be patterned to define one or more trenches exposing sidewalls of a respective one LED of the one or more LEDs and a surface of the backplane. Each trench can be filled with a color-shifting coating. The method includes laminating the one or more LEDs, the backplane, the protective layer, and the color-shifting coating between one or more inner reinforcing layers and one or more outer layers to define a display.