Stacked LED Layout for Uniform Large-Area Light Emission

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Solution Overview

Problem

Existing technologies face challenges in efficiently covering large areas with LEDs, as combining multiple light sources with optics to achieve uniform light distribution is costly and complex, while thin and flexible sources like OLEDs require numerous pixels and extensive electronic control, making them expensive for large-scale applications.

Innovation Solution

A light emitting device utilizing 2D material-based LEDs is developed, where LEDs are staggered and individually controlled to cover large areas with minimal electronics, allowing for tunable color perception and dimming by adjusting the output power of each LED, and utilizing insulating layers for electrical and functional separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If multiple LEDs of various colors are combined with optics to cover large areas, then light distribution uniformity is improved, but device complexity and cost increase

Engineering Contradiction:
Improvelight distribution uniformityVSAvoidoptics complexity
Core Design Contradiction:
Illumination intensityVSDevice complexity

Solution Approach 1:

The patent combines multiple LEDs of different colors (red, green, blue) into a single integrated device structure, merging their light emission functions to achieve uniform full-spectrum illumination across large areas without requiring separate optical systems for each color

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The integrated LED device performs multiple functions simultaneously - emitting red, green, and blue light from a single device structure, eliminating the need for separate single-color LED systems and complex optics to achieve uniform illumination

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If OLEDs are used to cover large areas, then flexibility is improved, but electronic control complexity increases

Engineering Contradiction:
ImproveflexibilityVSAvoidelectronic control complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The device divides the large-area illumination into multiple smaller LED units with distinct color emissions (red, green, blue LEDs), each unit being independently controllable, which simplifies the overall electronic control architecture compared to controlling numerous individual OLED pixels

Inventive Principle:
Principle #1Segmentation

3Area of stationary object

If LEDs are staggered to cover large areas, then area coverage is improved, but manufacturing complexity increases

Engineering Contradiction:
Improvearea coverageVSAvoidmanufacturing complexity
Core Design Contradiction:
Area of stationary objectVSEase of manufacture

Solution Approach 1:

The patent implements a staggered arrangement where smaller LED units are positioned in an offset pattern across the device area, with red, green, and blue LEDs interleaved in specific spatial relationships that maximize area coverage while maintaining manufacturable patterns

Inventive Principle:
Principle #7Nested doll (Nesting)

Solution Approach 2:

Different regions of the device contain different types of LEDs (red, green, blue) arranged in staggered patterns, with each local area contributing specific color emissions that combine to provide uniform full-spectrum illumination across the entire large area

Inventive Principle:
Principle #3Local quality

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, cost-effective coverage of large areas with homogeneous light emission, reducing the need for complex optics and extensive pixel control, while maintaining flexibility and reducing electronic complexity.

Implementation Method 1

a multi quantum well (MQW) semiconductor layer over the p-doped semiconductor layer

Methodology Applied
Scientific EffectElectroluminescence: Electroluminescence

Data Source

PatentUS12477863B2Light emitting device and method of making the same
Publication Date: 2025.11.18 PURDUE RES FOUND
  • US12477863B2 patent drawing
  • US12477863B2 patent drawing
  • US12477863B2 patent drawing

AI summary

A light emitting device includes a first light emitting diode (LED). The first LED includes a first metallic layer. The first LED additionally includes a first-doped semiconductor layer over the first metallic layer. Additionally, the first LED includes a multi quantum well (MQW) semiconductor layer over the first-doped semiconductor layer. Moreover, the first LED includes a second-doped semiconductor layer over the MQW semiconductor layer. Next, the first LED includes a second metallic layer over the second-doped semiconductor layer. The light emitting device also includes a second LED over the first LED. Further, the light emitting device includes a third LED over the second LED.