Micro-LED Mounting Board Reflector Geometry for Light Extraction
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Solution Overview
Problem
Existing light emitter mounting boards and display devices face challenges in enhancing light extraction efficiency and contrast due to limitations in the design of reflectors and light redirection, which hinder improved image quality.
Innovation Solution
A light emitter mounting board with a recessed reflective electrode on a sloped coating layer and a through-hole structure that gradually increases in thickness, allowing for efficient light reflection and redirection, combined with a micro-LED display device using a matrix arrangement of reflective electrodes for enhanced light extraction and contrast.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a planarizing layer and bank layer are used as reflectors, then light redirection in a predetermined direction is achieved, but light extraction efficiency and contrast are insufficient
Solution Approach 1:
The patent applies curvature by forming a recessed reflective electrode with a curved bottom surface in the mount area. This curved structure efficiently redirects light from micro-LEDs in a predetermined direction while improving light extraction efficiency compared to flat reflector structures. The curvature enables better light control and contrast enhancement.
Solution Approach 2:
The patent implements local quality by creating a coating layer with varying thickness - thinner at the opening and thicker toward the bottom. This non-uniform thickness distribution optimizes light reflection and redirection locally within the mount area, enhancing both light extraction efficiency and image quality without affecting the entire substrate uniformly.
2Ease of manufacture
If the coating layer has uniform thickness, then manufacturing is simpler, but light reflection and redirection efficiency is reduced
Solution Approach 1:
The coating layer is designed with non-uniform thickness, being thinner at the opening and thicker toward the bottom of the recessed structure. This local variation in thickness optimizes light reflection and redirection efficiency at different positions, achieving superior optical performance while remaining manufacturable through standard coating processes.
3Ease of manufacture
If the reflective electrode is flat, then manufacturing is easier, but light redirection in predetermined direction is insufficient
Solution Approach 1:
The reflective electrode is formed with a recessed curved bottom surface in the mount area rather than a flat surface. This curvature enables efficient redirection of light from micro-LEDs in a predetermined direction, significantly improving light extraction efficiency and display image quality while being compatible with standard manufacturing processes.
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 significantly improves light extraction efficiency and contrast by redirecting light emitted from micro-LEDs in a predetermined direction, resulting in improved image quality and display performance.
Implementation Method 1
each light emitter redirects light in a predetermined direction with a reflector
Data Source
AI summary
A light emitter mounting board for improving light extraction efficiency includes an insulating substrate, an electrode layer, a resin layer, a coating layer, and a reflective electrode. The resin layer is located on the electrode layer and has a through-hole portion extending in a thickness direction. The coating layer covers a surface of the resin layer and an inner peripheral surface of the through-hole portion. The coating layer includes an in-hole portion covering the inner peripheral surface and having a lateral thickness gradually increasing from the surface of the resin layer toward the electrode layer. The reflective electrode extends at least on a surface of the in-hole portion of the coating layer and on an exposed portion of a surface of the electrode layer.