Phosphor coatings for micro light-emitting diode (LED) displays

Patent metadata

Field	Value
Publication number	US-12342659-B2
Application number	US-202217866718-A
Country	US
Kind code	B2
Filing date	Jul 18, 2022
Priority date	Jul 18, 2022
Publication date	Jun 24, 2025
Grant date	Jun 24, 2025

Abstract

Aspects of the disclosure include light-emitting diodes (LEDs) formed without phosphor deformation during the lamination process. An exemplary method can include forming one or more LEDs on a backplane and forming a protective layer on the backplane. The protective layer can be patterned to define one or more trenches exposing sidewalls of a respective one LED of the one or more LEDs and a surface of the backplane. Each trench can be filled with a color-shifting coating. The method includes laminating the one or more LEDs, the backplane, the protective layer, and the color-shifting coating between one or more inner reinforcing layers and one or more outer layers to define a display.

First claim

What is claimed is:

1. A method comprising:
forming one or more light-emitting diodes (LEDs) on a backplane;
forming a protective layer on the backplane, the protective layer patterned to define one or more trenches, each trench exposing sidewalls of a respective one LED of the one or more LEDs and a surface of the backplane;
filling the trench with a color-shifting coating by depositing the color-shifting coating over the one or more LEDs, the protective layer, and the backplane until an overburden is formed above a surface of the protective layer and removing the overburden of the color-shifting coating to expose the surface of the protective layer; and
laminating the one or more LEDs, the backplane, the protective layer, and the color-shifting coating between one or more inner reinforcing layers and one or more outer layers to define a display.

2. The method of claim 1 , wherein the one or more LEDs are formed to a first height and the protective layer is formed to a second height greater than the first height.

3. The method of claim 2 , wherein forming the protective layer comprises progressively depositing a protective material on the backplane by spraying the protective material through a patterned mask to the second height.

4. The method of claim 1 , wherein removing the overburden comprises planarizing the color-shifting coating to a surface of the protective layer.

5. The method of claim 1 , wherein the color-shifting coating comprises at least one of red phosphors, yellow phosphors, and green phosphors.

6. The method of claim 1 , wherein the one or more inner reinforcing layers each comprise a polyvinyl butyral (PVB) film.

7. The method of claim 6 , wherein the one or more outer layers each comprise glass.

8. The method of claim 1 , further comprising dying the protective layer to match a color of the color-shifting coating.

9. A light-emitting diode (LED) display, the display comprising:
one or more light-emitting diodes (LEDs) on a backplane;
a protective layer on the backplane, the protective layer patterned to define one or more trenches, each trench exposing sidewalls of a respective one LED of the one or more LEDs and a surface of the backplane;
a color-shifting coating filling the trench;
one or more inner reinforcing layers; and
one or more outer layers;
wherein the one or more LEDs, the backplane, the protective layer, and the color-shifting coating are laminated between the one or more inner reinforcing layers and the one or more outer layers; and
wherein the protective layer is dyed to match a color of the color-shifting coating.

10. The display of claim 9 , wherein the one or more LEDs are formed to a first height and the protective layer is formed to a second height greater than the first height.

11. The display of claim 9 , wherein the protective layer comprises at least one of silicon and epoxy.

12. The display of claim 9 , wherein the one or more LEDs are formed in an array of N rows and M columns.

13. The display of claim 9 , wherein the one or more LEDs, the backplane, the protective layer, and the color-shifting coating together define a micro-LED layer having a thickness of 0.3 mm to 0.7 mm.

14. The display of claim 9 , wherein the color-shifting coating is planarized to a surface of the protective layer.

15. The display of claim 9 , wherein the color-shifting coating comprises at least one of red phosphors, yellow phosphors, and green phosphors.

16. The display of claim 9 , wherein the one or more inner reinforcing layers each comprise a polyvinyl butyral (PVB) film.

17. The display of claim 16 , wherein the one or more outer layers each comprise glass.

18. A light-emitting diode (LED) display, the display comprising:
one or more light-emitting diodes (LEDs) on a backplane;
a protective layer on the backplane, the protective layer patterned to define one or more trenches, each trench exposing sidewalls of a respective one LED of the one or more LEDs and a surface of the backplane;
a color-shifting coating filling the trench;
one or more inner reinforcing layers, each comprising a polyvinyl butyral (PVB) film; and
one or more outer layers;
wherein the one or more LEDs, the backplane, the protective layer, and the color-shifting coating are laminated between the one or more inner reinforcing layers and the one or more outer layers.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Park Jonglee
• Ellis Susan Carol

Classifications

• H10W90/00 Primary

  Package configurations · CPC title

• H10H20/0362

  of encapsulations · CPC title

• H10H20/8512 Primary

  Wavelength conversion materials · CPC title

• H10H20/854

  characterised by their material, e.g. epoxy or silicone resins · CPC title

• H10H20/851

  Wavelength conversion means · CPC title