Multi-colored Light Emitting Component via Selective Layer Removal
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Solution Overview
Problem
Existing methods for producing RGB displays face limitations in achieving small structural sizes and high power efficiency, with shadow mask technology restricted to sizes above 30 μm and color filter technology reducing power efficiency by filtering out most of the light spectrum.
Innovation Solution
A method involving the deposition of layer stacks over the entire substrate surface, followed by selective removal using energy beams like laser beams, allowing for smaller structural sizes and higher power efficiency by structuring after deposition, and electrically connecting cover layers to control radiation emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If shadow mask technology is used to produce RGB displays, then structural sizes can be maintained above 30 μm, but smaller structural sizes cannot be achieved
Solution Approach 1:
Instead of using a shadow mask to block deposition in certain areas, the patent inverts the approach by depositing complete layer stacks everywhere and then selectively removing material in unwanted areas. This allows achieving smaller structural sizes below 30 μm without the handling limitations of shadow masks, while maintaining manufacturing feasibility through established etching processes.
Solution Approach 2:
The patent extracts the unwanted portions of layer stacks through selective removal processes after complete deposition. This enables precise definition of small RGB pixel structures by removing material in specific patterns, achieving structural sizes below 30 μm that would be impossible with shadow mask limitations.
2Length of moving object
If color filter technology is used to generate RGB colors, then small structural sizes can be achieved, but power efficiency is reduced by filtering out most of the light spectrum
Solution Approach 1:
Instead of using color filters that waste most of the light spectrum, the patent converts the approach to directly emit the desired colors through selective layer deposition. Each RGB pixel emits its specific color wavelength range directly from the light-emitting layers, eliminating the energy loss associated with filtering out unwanted wavelengths and achieving high power efficiency while maintaining small structural sizes.
3Length of moving object
If layer stacks are deposited over the entire substrate surface and then selectively removed, then smaller structural sizes in the one-digit micrometer range can be achieved, but process complexity increases
Solution Approach 1:
The patent performs preliminary complete deposition of all layer stacks across the entire substrate before any selective removal operations. This preliminary action simplifies the overall process by using single-step deposition techniques that cover the whole surface, followed by patterned removal to define the final small RGB pixel structures in the one-digit micrometer range.
Solution Approach 2:
The patent applies local quality by selectively removing layer stacks from specific partial surface areas to create the RGB pixel pattern. Different regions of the substrate receive different treatments - some areas have layer stacks removed while others retain them, creating the desired color pattern with high precision at micrometer scale.
4Loss of energy
If cover layers are electrically connected to control radiation emission, then power efficiency and brightness are improved, but electrical connection complexity increases
Solution Approach 1:
The patent merges the cover layers electrically by establishing conductive connections between adjacent cover layers. This merging allows the cover layers to function collectively as a common electrode, enabling efficient control of radiation emission across multiple RGB pixels while reducing the need for separate electrical connections for each pixel, thus improving power efficiency without excessive complexity.
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
Enables the production of components with structural sizes in the one-digit micrometer range and higher power efficiency compared to existing technologies, achieving smaller features and improved brightness.
Implementation Method 1
the layer stack is removed from a partial surface area by means of an energy beam
Implementation Method 2
a first layer stack, which comprises at least one layer, which causes the emission of the electromagnetic radiation in the first wavelength range
Data Source
AI summary
A method for producing a component is provided, where the component comprises a substrate, which emits at least one electromagnetic radiation in a first wavelength range and an electromagnetic radiation in a second wavelength range within one surface area. Electrodes can be formed within the surface area of the substrate; a first layer stack can be deposited, comprising at least one layer, which causes the emission of the electromagnetic radiation in the first wavelength range, and a cover layer, acting as the first counterelectrode, on the entire surface area; the first layer stack can be removed from a first partial surface area, which comprises at least one electrode; a second layer stack can be deposited, comprising at least one layer, which causes the emission of the electromagnetic radiation in the second wavelength range, and a second cover layer, acting as the counterelectrode, on the entire surface area.