Three-in-one RGB Mini-LED Device Using Quantum Dot Filter
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Solution Overview
Problem
Conventional RGB LED technologies require multiple light wavelength materials for different colors, leading to complex manufacturing processes and limited customization in shape and size for RGB LED lamps and displays.
Innovation Solution
A three-in-one RGB mini-LED device utilizing a single light source wavelength material combined with a quantum dot filter, employing a flip-chip process to create RGB quantum dot materials, allowing for smaller size, higher light utilization, and precision-controlled lighting patterns, as well as customizable shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple light wavelength materials are used for different colors in conventional RGB LED, then different color light effects can be achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent introduces a quantum dot filter layer as an intermediary component between the single-wavelength blue LED and the human eye. This quantum dot filter converts the blue light into red and green wavelengths through photoluminescence, enabling full RGB color output without requiring multiple wavelength materials in the LED structure itself, thus simplifying the manufacturing process while maintaining color versatility
Solution Approach 2:
The patent changes the optical parameters by using a single blue wavelength LED combined with a quantum dot filter that emits multiple wavelengths (red and green). This parameter transformation approach allows the system to achieve multiple color outputs from a single wavelength input, resolving the contradiction between color versatility and manufacturing complexity
2Ease of manufacture
If conventional LED structure is used, then standard manufacturing processes can be applied, but RGB LED lamps cannot be customized in shape and size
Solution Approach 1:
The patent segments the conventional LED structure into functional layers (substrate, quantum dot filter layer, light-emitting layer, protective layer) that can be independently manufactured and then assembled. This segmentation allows the light-emitting portion to be customized in various shapes and sizes while maintaining standardized manufacturing processes for each layer, enabling both ease of manufacture and design flexibility
Solution Approach 2:
The patent adds the dimension of modular layering to the traditional monolithic LED structure. By stacking functional layers that can be separately manufactured and assembled, the system enables customization in shape and size without requiring complete redesign of the entire manufacturing process, thus resolving the contradiction between standardization and customization
3Reliability
If flip-chip process is used in the present disclosure, then lateral sides of electrical semiconductor layers are less likely to be damaged, but the structure becomes more complex
Solution Approach 1:
The patent inverts the conventional chip mounting orientation by using a flip-chip process where the LED chip is mounted upside down, with the light-emitting surface facing downward toward the quantum dot filter. This inversion protects the vulnerable lateral sides of the semiconductor layers from damage during packaging and operation, as the protective layer now covers these previously exposed surfaces, accepting the increased structural complexity as a necessary trade-off for improved reliability
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 enables efficient production of RGB mini-LEDs with improved light utilization and precision-controlled lighting, allowing for customized shapes and sizes, addressing the complexity and limitations of existing technologies.
Implementation Method 1
a quantum dot filter to emit lights in three colors of RGB
Data Source
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AI summary
A three-in-one RGB mini-LED device includes a substrate (10), a second electrical semiconductor layer (12), a plurality of multiple-quantum well layers (13), a plurality of first electrical semiconductor layers (11), and a plurality of mirrors (14). The second electrical semiconductor layer (12) is disposed on the substrate (10). The plurality of multiple-quantum well layers (13) are disposed on the second electrical semiconductor layer (12). An area of each of the plurality of multiple-quantum well layers (13) is smaller than an area of the second electrical semiconductor layer (12), and a region on the second semiconductor layer (12) is not covered by the plurality of multiple-quantum well layers (13).