Selective Conversion Layer Application for Small Pixel LED Displays
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Solution Overview
Problem
Existing methods for producing multicolor LED displays with small pixel sizes are complex and require significant adjustment, especially when using two different conversion substances, making them unsuitable for LED displays with pixel sizes less than 100 μm.
Innovation Solution
A method involving the use of first and second conversion layers applied or removed in defined regions above the pixels, utilizing electromagnetic radiation, heat, or electric fields to selectively convert blue light into green and red light, allowing for the production of multicolor displays without the need for complex masking processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conversion layers are selectively applied to LED chips using laminae, then multicolor LED displays can be realized, but the production process becomes very complex especially for small pixel sizes
Solution Approach 1:
The invention divides the LED chip surface into multiple defined regions (first, second, and third regions) that correspond to different subpixel areas. Conversion layers are selectively applied to specific regions rather than uniformly across the entire chip, enabling precise color control for each subpixel while simplifying the overall manufacturing process.
Solution Approach 2:
Different conversion layers are applied to different regions of the LED chip based on local requirements. The first conversion layer is applied to the second region, the second conversion layer to the third region, and both layers to the first region, creating local variations in optical properties that generate different colors from a single blue LED chip.
2Adaptability or versatility
If both first and second conversion layers are applied to produce RGB display, then multicolor output is achieved, but the adjustment outlay increases considerably
Solution Approach 1:
A single blue-emitting LED chip structure serves multiple functions by combining different conversion layers in different regions. The same basic LED chip design can produce blue, green, and red colors through regional variation in conversion layer application, eliminating the need for separate LED chips for each color and reducing adjustment complexity.
Solution Approach 2:
The conversion layers are applied in a predetermined sequence and pattern during the manufacturing process. The first conversion layer is applied to specific regions, then the second conversion layer is applied to other regions, creating the final multicolor pattern in advance before the LED modules are assembled and adjusted.
3Reliability
If conversion layers are applied to all pixels, then color conversion is achieved, but selective color output requires complex removal processes
Solution Approach 1:
The invention avoids the need for complex removal processes by selectively applying conversion layers to different regions from the beginning. Instead of applying layers uniformly and then removing them, the manufacturing process directly places conversion layers only where needed in the first, second, and third regions, simplifying the overall process.
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 method enables the production of multicolor LED displays with low production and adjustment outlay, particularly suitable for small pixel sizes, by selectively applying and removing conversion layers using electromagnetic radiation, heat, or electric fields, thereby simplifying the process and reducing complexity.
Implementation Method 1
a first conversion layer that converts radiation of the first color into radiation of the second color
Implementation Method 2
a second conversion layer that converts radiation of the first color and/or the radiation of the second color into radiation of the third color
Implementation Method 3
an LED chip that emits radiation of the first color
Data Source
AI summary
A method produces a multicolor LED display, the display including an LED luminous unit having a multiplicity of pixels. First subpixels, second subpixel and third subpixels contain an LED chip that emits radiation of a first color, wherein a first conversion layer that converts the radiation into a second color is arranged at least above the second subpixels and a second conversion layer that converts the radiation into a third color is arranged above the third subpixels. At least one process step is carried out in which the first or second conversion layer is applied or removed in at least one defined region above the pixels, wherein a portion of the LED chips is electrically operated, and wherein the region is defined by the radiation generated by the operated LED chips, generated heat or a generated electric field.