Silazane Phosphor Coating for Precise Micro-LED Color Curing
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Solution Overview
Problem
Current manufacturing processes for optoelectronic devices, such as LEDs and micro-LEDs, face challenges in achieving uniform and stable color distribution and temperature due to variations in wavelength converting materials, leading to inconsistent color points and thermal stress issues during high-temperature curing.
Innovation Solution
A process involving multiple layers of a formulation containing a silazane polymer and wavelength converting materials, where each layer is precured using radiation and then cured with heat or radiation, allowing for precise control of color point and reduced thermal stress through lower temperature curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If high temperature curing is used to cure the wavelength converting material layer, then the curing speed is improved, but thermal stress and damage to the LED precursor increases
Solution Approach 1:
The curing process is divided into multiple sequential curing steps rather than a single high-temperature step. Each layer is cured individually at controlled temperatures, allowing the thermal stress to be distributed and managed throughout the manufacturing process, thus preventing damage to the LED precursor while maintaining efficient curing speed.
Solution Approach 2:
The wavelength converting material layer is applied and prepared on the LED precursor before the final curing step. This preliminary positioning allows for optimized curing conditions to be applied subsequently, reducing the need for excessive heat during the actual curing process and thereby minimizing thermal stress on the precursor.
2Manufacturing precision
If multiple wavelength converting materials are used to achieve desired color point, then color precision is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process segments the application and curing of different wavelength converting materials into separate, sequential steps. Each material layer is applied and cured independently, which simplifies the control of each individual step while achieving the desired overall color precision through the combination of multiple layers with different emission characteristics.
Solution Approach 2:
Different wavelength converting materials are applied to different regions or layers of the LED device, with each material optimized for specific color coordinates. This local optimization allows precise control of the overall color point by combining materials with complementary emission properties, achieving high color precision without requiring all materials to be processed simultaneously.
3Stability of the object's composition
If uniform coating of wavelength converting materials is achieved, then color uniformity is improved, but manufacturing time increases
Solution Approach 1:
The coating and curing process is segmented into multiple thin layers rather than applying a single thick layer. Each thin layer can be coated more uniformly and cured quickly, reducing the time required per layer. The cumulative effect of multiple uniformly coated layers achieves the desired overall color uniformity while the total manufacturing time remains manageable due to the reduced curing time per layer.
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 results in optoelectronic devices with improved barrier properties, enhanced color point stability, and better mechanical and thermal stability, enabling cost-effective and efficient large-scale production with precise color adjustment.
Implementation Method 1
precured by exposure to radiation
Implementation Method 2
cured by exposure to heat or radiation
Implementation Method 3
wavelength converting materials such as e.g. phosphors or semiconductor nanoparticles (quantum materials) are used
Data Source
AI summary
The present invention relates to a process for manufacturing an optoelectronic device, wherein a layer of a formulation containing a silazane polymer and a wavelength converting material is applied to an optoelectronic device precursor, precured by exposure to radiation and then cured. There is further provided an optoelectronic device, preferably a light emitting device (LED) or a micro-light emitting device (micro-LED), which is prepared by said manufacturing process.