Quantum Dot Light-Conversion Structure for Transfer-Free RGB Micro-LEDs
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Solution Overview
Problem
Current methods for fabricating micro-LED displays are complex, involving the singulation, sorting, and transfer of blue, red, and green micro-LEDs from separate wafers, which complicates the process and reduces efficiency.
Innovation Solution
A semiconductor device comprising a light-emitting structure with embedded quantum dots in nanoporous structures, where the light-conversion device is formed on the light-emitting device, enhancing color purity and conversion efficiencies, and allowing for the integration of micro-LEDs emitting different colors on a single substrate without the need for individual transfer and sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate wafers are used for blue, red, and green micro-LEDs, then color purity is maintained, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple light-emitting devices emitting different colors (blue, red, green) onto a single substrate, merging what were previously separate fabrication processes into one unified structure. This reduces the number of wafers needed and simplifies the overall manufacturing process while maintaining color purity through spatial separation of the different colored LEDs on the same substrate.
Solution Approach 2:
The substrate serves multiple functions by supporting different types of light-emitting devices (blue, red, green micro-LEDs) simultaneously. This multi-functional substrate eliminates the need for separate specialized wafers for each color, reducing manufacturing complexity while preserving the color-specific performance of each LED type.
2Manufacturing precision
If separate wafers are used for different colored micro-LEDs, then color specificity is maintained, but productivity decreases
Solution Approach 1:
By merging the fabrication of blue, red, and green micro-LEDs into a single substrate processing operation, the patent increases productivity. Instead of separately manufacturing and then assembling LEDs from multiple wafers, the unified approach allows simultaneous fabrication of all color types in one process flow, significantly reducing production time and提高效率.
Solution Approach 2:
The patent performs preliminary actions by pre-arranging the spatial layout of different colored micro-LEDs on the substrate during the initial fabrication process. This preliminary positioning and integration eliminates subsequent sorting and transfer steps, streamlining the production process and enhancing overall fabrication efficiency.
3Power
If quantum dots are embedded in nanoporous structures, then color conversion efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes nanoporous structures as the host matrix for embedding quantum dots. The porous architecture provides high surface area and numerous anchoring sites for quantum dot attachment, enhancing light conversion efficiency. The nanoporous material serves as both structural support and functional medium for color conversion, optimizing performance while managing complexity through material selection.
Solution Approach 2:
The patent creates a composite structure by combining quantum dots with nanoporous materials. This composite approach integrates two functional components (quantum dots for color conversion and nanoporous material for structural support and enhanced surface area) into a single unified layer, improving light conversion efficiency while consolidating multiple functions into one integrated structure.
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
This approach simplifies the fabrication of micro-LED displays by integrating red, green, and blue micro-LEDs on a single substrate, improving color purity and conversion efficiencies, and enabling more efficient production processes.
Implementation Method 1
a first plurality of quantum dots for converting light produced by the first light-emitting device into light of a first color
Data Source
AI summary
In accordance with one or more aspects of the present disclosure, a semiconductor device is provided. The semiconductor device may include: a plurality of light-emitting devices comprising a first light-emitting device, a second light-emitting device, and a third light-emitting device; and a light-conversion device with embedded quantum dots. In some embodiments, a first portion of the light-conversion device includes a first plurality of quantum dots for converting light produced by the first light-emitting device into light of a first color, and a second portion of the light-conversion device includes a second plurality of quantum dots for converting light produced by the second light-emitting device into light of a second color. The third light-emitting device emits light of a third color.