Transfer Substrate Phosphor Patterning for High-Resolution LED Displays
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Solution Overview
Problem
Current display technologies, such as LCD and OLED, face challenges in achieving short response time, flexibility, and high-resolution applications, while light emitting diodes (LEDs) offer advantages like long lifespan and low power consumption, but struggle with forming partition wall structures for high-resolution displays.
Innovation Solution
A transfer substrate with a phosphor structure, including a phosphor, phosphor binder, and color filter, is used to form a partition wall structure and phosphor pattern on light emitting semiconductor devices, enabling divisional transfer and high-resolution applications without separate partition walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a partition wall structure is used to prevent color mixing in phosphor conversion layers, then color accuracy is improved, but device complexity and manufacturing difficulty increase for high-resolution applications
Solution Approach 1:
The invention segments the phosphor conversion layer into multiple discrete phosphor patterns, each corresponding to a specific sub-pixel region. This segmentation eliminates the need for continuous partition walls while maintaining color separation, thereby reducing manufacturing complexity for high-resolution displays
Solution Approach 2:
The invention extracts and removes the partition wall structure from the display device architecture. By using discrete phosphor patterns with sufficient spacing, the patent eliminates the harmful partition walls that complicate manufacturing, while still achieving effective color separation through the phosphor pattern arrangement
2Device complexity
If discrete phosphor patterns are formed for each sub-pixel, then manufacturing complexity is reduced, but color mixing prevention becomes insufficient
Solution Approach 1:
The invention applies local quality by positioning specific phosphor materials with distinct emission characteristics in precise locations corresponding to red, green, and blue sub-pixels. Each phosphor pattern has optimized local properties (material composition, particle size, concentration) to ensure accurate color emission without requiring partition walls
Solution Approach 2:
The invention uses excessive spacing between phosphor patterns and optimizes phosphor layer thickness to prevent color mixing. By providing sufficient separation distance and controlling phosphor layer parameters, the patent achieves color isolation without needing partition walls, effectively using partial action to achieve the separation function
3Manufacturing precision
If partition walls are formed to separate phosphor regions, then color conversion accuracy is improved, but the number of manufacturing steps increases
Solution Approach 1:
The invention merges the phosphor pattern formation process with the LED chip mounting process. By transferring pre-formed phosphor patterns to the LED chip surface in a single step, the patent combines multiple manufacturing operations into one, eliminating separate partition wall formation steps and improving manufacturing throughput
Solution Approach 2:
The invention performs preliminary action by pre-forming phosphor patterns on a separate substrate before transferring them to the LED chip. This allows phosphor patterns to be prepared in advance with high precision, and then transferred in a single batch process, eliminating the need for step-by-step partition wall formation during LED assembly
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 solution allows for the formation of phosphor patterns on LEDs, reducing defects and the number of redundant cells, and enabling flexible, high-resolution displays with improved luminance and color conversion efficiency.
Implementation Method 1
a phosphor conversion layer arranged on the base substrate, the phosphor conversion layer including divided unit phosphor structures transferred onto the light emitting semiconductor device
Implementation Method 2
a color filter arranged between the base substrate and the phosphor binder
Data Source
AI summary
Disclosed herein is a transfer substrate used for manufacturing a display device using a light emitting semiconductor device. The transfer substrate include a base substrate, and a divided unit phosphor structure arranged on the base substrate and transferred onto the light emitting semiconductor device.