Patterned LED Structure for Dual-Wavelength Backlight Chips
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Solution Overview
Problem
Traditional LED backlight chips have low color gamut due to inefficient combination of blue light LEDs with phosphors, leading to poor color fidelity and high production costs associated with green light phosphors.
Innovation Solution
An LED structure with a substrate having alternating regions for different light-emitting units, where a patterned mask layer suppresses epitaxial growth to achieve distinct light-emitting wavelengths, and an encapsulation adhesive with phosphors to enhance color gamut, simplifying manufacturing and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a blue light LED is combined with yellow light phosphor to realize white light LED, then the manufacturing process is simple, but the color gamut is low resulting in low color fidelity
Solution Approach 1:
The LED chip is divided into multiple light-emitting regions with different semiconductor layers that emit different wavelengths (blue, green, red). Each region is independently designed to emit specific wavelengths, and these segmented light emissions are combined to produce white light with high color gamut while maintaining a single integrated chip structure
Solution Approach 2:
Different regions of the LED chip are assigned different semiconductor layer compositions and structures to achieve different light-emitting characteristics. The first light-emitting region uses semiconductor layers for blue light emission, the second region uses semiconductor layers for green light emission, and the third region uses semiconductor layers for red light emission, allowing each local area to have optimized properties for its specific function
2Manufacturing precision
If a blue light LED is combined with green light phosphor and red light phosphor to achieve higher color gamut, then the color gamut performance is improved, but the efficiency of blue light LED to trigger green light phosphor is low and the production cost is high
Solution Approach 1:
The patent replaces the phosphor-based wavelength conversion mechanism with a direct light-emitting mechanism using multiple semiconductor layers. Instead of using blue light LED to trigger green phosphor (which has low efficiency), the invention uses a second light-emitting region with semiconductor layers that directly emit green light, eliminating the inefficient phosphor conversion process and energy loss
Solution Approach 2:
The patent changes the fundamental parameter of light generation from wavelength conversion (phosphor excitation) to direct emission (semiconductor electroluminescence). By changing the generation mechanism and using semiconductor layers with different bandgaps in different regions, the system achieves high color gamut with direct efficient light emission rather than indirect phosphor conversion
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 LED structure achieves two main light-emitting wavelengths on a single substrate, effectively addressing low color gamut issues while reducing production costs and simplifying manufacturing processes.
Implementation Method 1
The light-emitting unit includes a first semiconductor layer, a light-emitting layer and a second semiconductor layer that are stacked in sequence
Implementation Method 2
The encapsulation adhesive covers an upper surface and sidewalls of the LED structure, and the encapsulation adhesive includes a phosphor material
Data Source
AI summary
Disclosed are an LED structure, an LED device, and a manufacture method for the LED structure. The LED structure includes a substrate structure, and a first region and a second region are periodically provided in the substrate structure. The substrate structure includes a substrate and at least one patterned mask layer located on the substrate, the at least one patterned mask layer is located in the second region, and patterned mask layer in each second region are periodically provided. A light-emitting unit is located on the substrate structure, the light-emitting unit includes a first sub-light-emitting structure located in the first region and a second sub-light-emitting structure located in the second region, and light-emitting wavelengths of the first sub-light-emitting structure and the second sub-light-emitting structure are different. A light-emitting unit with two main light-emitting wavelengths is realized on a same substrate.