Tri-Color Light Bead Structure for Simpler Micro-LED Mass Transfer
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Solution Overview
Problem
The assembly process for Micro-LED displays is complex and inefficient due to the need for precise mass transfer of multiple RGB chips, leading to low production yield and high requirements on the mass transfer process.
Innovation Solution
A light bead structure that integrates a light-emitting chip, diffusing and collimating assembly, and a light-exiting layer with multiple phosphors and films to emit three primary colors from a single bead, reducing the number of beads required in the mass transfer process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple RGB chips are arranged and mass-transferred to achieve full-color display, then color reproduction is improved, but mass transfer process complexity increases and production yield decreases
Solution Approach 1:
The patent merges the functions of red, green, and blue light emission into a single light bead by integrating multiple light-emitting chips and phosphor layers within one bead structure. This consolidation reduces the number of separate chips that need to be mass-transferred and assembled, thereby simplifying the mass transfer process while maintaining full-color display capability.
Solution Approach 2:
The light bead is designed as a multi-functional unit that can emit red, green, and blue light simultaneously or independently through its integrated phosphor layers and light-emitting chips. This universal design allows a single bead to perform the functions previously requiring multiple separate RGB chips, reducing assembly complexity and improving production yield.
2Adaptability or versatility
If multiple RGB chips are arranged in specific patterns to achieve color effect, then color quality is improved, but assembly process complexity increases
Solution Approach 1:
The patent combines multiple light-emitting chips and phosphor materials into a single integrated light bead structure. This merging eliminates the need for complex sequential arrangement and assembly of separate red, green, and blue chips on the substrate, significantly simplifying the manufacturing process while maintaining high color quality through the integrated phosphor conversion layers.
3Adaptability or versatility
If a large number of chips are mass-transferred to achieve RGB effect, then display color range is improved, but production yield decreases
Solution Approach 1:
The patent merges multiple light-emitting functions into a single light bead, reducing the total number of chips that need to be mass-transferred. This consolidation increases production yield by reducing the complexity and failure rate of the mass transfer process, while the integrated phosphor layers ensure that the full color range is maintained through effective light conversion.
Solution Approach 2:
The light bead is designed as a multi-functional unit that can generate all three primary colors (red, green, blue) through its integrated phosphor layers excited by the light-emitting chips. This universal design allows fewer beads to be transferred compared to traditional separate RGB chip arrangements, thereby improving production yield while maintaining comprehensive color display capability.
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 structure lowers the requirements on the mass transfer process and improves the production yield and assembly efficiency of Micro-LED displays by allowing a single light bead to emit all three primary colors, simplifying the installation process.
Implementation Method 1
The light diffusing and collimating assembly is arranged on a light-exiting side of the light-emitting chip, and is configured to diffuse the light rays emitted from the light-emitting chip and adjust the light rays to be emitted at mutually parallel angles
Implementation Method 2
The first light-emitting region includes a first color phosphor and a first color film. After passing through the first light-emitting region, the light forms a first color light
Implementation Method 3
The second light-emitting region includes a second color phosphor and a second color film. After passing through the second light-emitting region, the light forms a second color light
Data Source
AI summary
A light bead, a light plate, and a display device are disclosed. The light bead includes a light-emitting chip disposed at a bottom of the light bead, a light diffusing and collimating assembly disposed on a light-exiting side of the light-emitting chip, and a light-exiting layer. The light-exiting layer includes a first, a second, and a third light-emitting region, and two baffles. When the light-emitting chip is in operation, the emitted light passes through the light diffusing and collimating assembly and enters each of the first, the second, and the third light-emitting region, thus forming a first color light after passing through the first light-emitting region, a second color light after passing through the second light-emitting region, and not changing the color of the light after passing through the third light-emitting region, so that the light bead is able to emit light in three different colors.