Emissive display with printed light modification structures

• US 10,520,769 B2
• Filed: 01/23/2017
• Issued: 12/31/2019
• Est. Priority Date: 10/31/2014
• Status: Active Grant

• Current Assignee: Elux Inc.
• Original Assignee: Elux Inc.
• Inventors: Ulmer, Kurt, Lee, Jong-Jan, Sasaki, Kenji, Schuele, Paul J.
• Primary Examiner(s): Lee, Y M.
• Application Number:
  US15/413,053
• Publication Number:
  US 20170139276A1
• Time in Patent Office: 1,072 Days
• CPC Class Codes: G02F 1/133603 with LEDs
• CPC Class Codes: G02F 1/133606 including a specially adapted diffusing, scattering or light controlling members
• CPC Class Codes: G02F 1/133614 using photoluminescence, e.g. phosphors illuminated by UV or blue light
• CPC Class Codes: G02F 1/133621 providing coloured light G02F1/133617, G02F1/133533 take precedence
• CPC Class Codes: G02F 2202/36 Micro- or nanomaterials

Abstract

A multi-color emissive display is presented with printed light modifier structures. A fabrication method provides an emissive substrate with a plurality of wells formed in the emissions substrate top surface, and a plurality of emissive elements populating the wells. The method prints light modifier structures overlying the emissive elements. Some examples of light modifier material include light scattering materials, phosphors, and quantum dots. In one aspect, the emissive substrate wells have a first shape, with sidewalls and a first perimeter. Likewise, the emissive elements have the first shape, with sides and a second perimeter, less than the first perimeter. The light modifier structures fill the space between the emissive element sides and the well sidewalls with light modifier material. If the first shape is circular, the method prints the light modifier structures overlying the emissive elements in the circular shape having a first diameter defined by the well sidewalls.

Claims

1. A multi-color emissive display comprising:

an emissions substrate comprising;

a top surface;

a plurality of wells formed in the emissions substrate top surface;

a matrix of column and row conductive traces forming a first plurality of column/row intersections, where each column/row intersection is connected to an electrical contact of a corresponding well;

a plurality of emissive elements populating the wells, each emissive element having a bottom surface;

printed light modifier structures overlying a plurality of the emissive element bottom surfaces, wherein the printed light modifier structures comprise a material selected from a group consisting of high refractive index polymer spheres, phosphors, and quantum dots (QDs).

2. The display of claim 1 wherein each well has a cross-sectional area with a first shape, sidewalls orthogonal to the cross-sectional area, and a first perimeter around the sidewalls;

wherein each emissive element is formed with a cross-sectional area having the first shape, sides orthogonal to the emissive element cross-sectional area, and a second perimeter around the sides, less than the first perimeter; and

,

wherein the printed light modifier structures fill a space between the emissive element sides and the well sidewalls.

3. The display of claim 2 wherein the first shape is circular.

4. The display of claim 2 wherein the printed light modifier structures have a cross-sectional area with the first shape, sides orthogonal to the printed light modifier structure cross-sectional area, and a first perimeter around the printed light modifier structures defined by the well sidewalls.

5. The display of claim 1 wherein each emissive substrate well has a bottom surface with a first electrical interface formed on the bottom surface and a second electrical interface formed on the bottom surface, both operatively connected to a corresponding column/row intersection;

wherein each emissive element is a surface mount emissive element with a top surface overlying a corresponding well bottom surface, with a first electrical contact formed on the emissive element top surface electrically connected to the first electrical interface, and with a second electrical contact formed on the emissive element top surface electrically connected to the second electrical interface; and

,

wherein the light modification structures are formed overlying the emissive element bottom surfaces without an intervening emissive element metal interconnection layer.

6. The display of claim 1 wherein each well has a first volume, as defined with the well unpopulated by an emissive element;

and,

wherein a second volume of material fills each populated well, where the second volume is greater than the first volume and includes the volume of the emissive element and the volume of the light modifier material.

7. The display of claim 1 further comprising:

a liquid crystal display (LCD) substrate including red-green-blue (RGB) color pixels;

wherein the emissive substrate is an LCD backlight;

wherein the emissive elements are blue light-emitting light emitting diodes (LEDs); and

,

wherein the light modifier structures overlying the LEDs convert blue light to white light using phosphor or QD color conversion materials selected from the group consisting of either a combination of red and green color conversion materials or a yellow color conversion material.

8. A multi-color emissive display fabrication method, the method comprising:

providing an emissive substrate comprising;

a top surface, with a plurality of wells formed in the emissions substrate top surface, and a plurality of emissive elements populating the wells, each emissive element having a bottom surface with an electrical interface connected to an electrical contact on a well bottom surface; and

,

printing light modifier structures overlying the emissive element bottom surfaces, wherein the light modifier structures comprise a material selected from a group consisting of high refractive index polymer spheres, phosphors, and quantum dots (QDs).

9. The method of claim 8 wherein providing the emissive substrate wells includes providing wells having a cross-sectional area with a first shape, sidewalls orthogonal to the cross-sectional area, and a first perimeter around the sidewalls;

wherein providing the emissive elements includes providing emissive element having a cross-sectional area with the first shape, sides orthogonal to the emissive element cross-sectional area, and a second perimeter around the sides, less than the first perimeter; and

,

wherein printing light modifier structures includes filling a space between the emissive element sides and the well sidewalls with light modifier material.

10. The method of claim 9 wherein the first shape is circular.

11. The method of claim 9 wherein printing the light modifier structures includes printing the light modifier structures having a cross-sectional area with the first shape.

12. The method of claim 11 wherein the light modifier structures have sides orthogonal to the light modifier structure cross-sectional area, with a first perimeter around the light modifier structure sides defined by the well sidewalls.

13. The method of claim 8 wherein printing the light modifier structures includes inkjet printing the light modifier structures.

14. The method of claim 8 printing the light modifier structures includes:

printing a liquid phase mixture of matrix material with QDs or a phosphor; and

,

annealing the emissive substrate to cure the matrix material.

15. The method of claim 14 wherein the matrix material is selected from the group consisting of silicon, acrylic, and epoxy.

16. The method of claim 8 wherein printing the light modifier structures includes:

depositing a liquid phase light modifier material overlying the wells; and

,

defining the liquid phase light modifier material cross-sectional area shape in response to the cross-sectional area shape of the underlying well.

17. The method of claim 8 wherein printing the light modifier structures includes:

printing a liquid phase mixture of matrix material and light scattering materials; and

,

annealing the emissive substrate to cure the matrix material.

18. The method of claim 8 wherein providing the emissive substrate wells includes providing wells having a first volume, as defined with the well unpopulated by an emissive element;

and,

wherein printing the light modifier structure includes filling each well with enough light modifier material to form a second volume, where the second volume is greater than the first volume and includes both the volume of the emissive element and the volume of the printed light modifier material.

19. An emissive display comprising:

an emissions substrate comprising;

a top surface;

a plurality of wells formed in the emissions substrate top surface;

a matrix of column and row conductive traces forming a first plurality of column/row intersections in the substrate, where each column/row intersection is connected to an electrical contact of a corresponding well;

a plurality of emissive elements populating the wells, each emissive element having a bottom surface, a top surface overlying a well bottom surface, and a post extending from the emissive element bottom surface;

printed light modifier structures overlying a plurality of the emissive element bottom surfaces.