Reflective Opening Layout for High-Resolution Micro-LED Displays
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Solution Overview
Problem
The challenge in manufacturing high-resolution display devices, such as micro-LED displays, lies in efficiently arranging and transferring small-sized LED chips to achieve optimal light emission and minimize light leakage, which existing technologies have not adequately addressed.
Innovation Solution
The proposed display device design includes a substrate with an emission layer and a reflective layer, where the emission region overlaps the reflective layer's opening, and light extraction patterns are used to optimize light transmission and extraction efficiency, ensuring that light is emitted at the maximum transmission incidence angle without total reflection, thereby enhancing light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If small size LED chips are used to manufacture high-resolution display devices, then the resolution and pixel density are improved, but the difficulty of arranging and transferring the chips increases and light leakage becomes more problematic
Solution Approach 1:
The device is segmented into distinct functional layers (emission layer, reflective layer, insulating layers) with the reflective layer containing multiple openings positioned beneath emission regions. This segmentation allows independent optimization of each layer's function while managing the complexity of high-resolution chip arrangement.
Solution Approach 2:
The reflective layer is designed with non-uniform local properties - it has openings in specific regions beneath emission regions and reflective surfaces in other regions. This local quality variation optimizes light extraction where needed while preventing light leakage in adjacent areas, addressing the challenges of high-resolution display without requiring uniform complex structures throughout.
2Use of energy by moving object
If the opening width in the reflective layer is increased to improve light extraction, then light transmission efficiency is improved, but light leakage increases
Solution Approach 1:
The reflective layer exhibits spatially varying properties with openings positioned directly beneath emission regions to maximize light extraction efficiency, while adjacent regions maintain reflective surfaces that prevent light leakage. This local differentiation resolves the contradiction between extraction efficiency and leakage prevention.
Solution Approach 2:
The reflective layer converts potentially harmful light leakage into beneficial light extraction by positioning reflective surfaces and openings strategically - light that would otherwise leak is redirected through the openings toward the viewer, transforming a harmful effect into a beneficial one while maintaining high extraction efficiency.
3Use of energy by moving object
If light is emitted at maximum transmission incidence angle to optimize extraction, then light extraction efficiency is improved, but total reflection occurs at interfaces
Solution Approach 1:
An insulating layer with intermediate refractive index is introduced between the emission layer and the reflective layer, serving as an optical intermediary that reduces refraction and total internal reflection at interfaces. This mediator enables light to be emitted at maximum transmission incidence angles while maintaining reliable transmission through the layered structure.
Solution Approach 2:
The refractive index parameter is modified by introducing the insulating layer with an intermediate value between the emission layer and reflective layer. This parameter change reduces the abruptness of refractive index transitions, thereby reducing total internal reflection and enabling more reliable light transmission at high incidence angles while maintaining extraction efficiency.
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 design significantly improves light extraction efficiency by ensuring that light is effectively transmitted through the emission layer and reflected by the reflective layer, reducing light leakage and enhancing the overall performance of high-resolution display devices.
Implementation Method 1
a reflective layer provided on the emission layer, the reflective layer comprising a first opening
Implementation Method 2
an emission layer provided on the substrate, the emission layer comprising an emission region that emits light
Data Source
AI summary
A display device includes a substrate, an emission layer provided on the substrate and a reflective layer provided on the emission layer. The emission layer has an emission region that emits light, the reflective layer has a first opening, the emission region overlaps the first opening in a direction perpendicular to an upper surface of the substrate and a first width of the emission region is smaller than a second width of the first opening.