Active Matrix LED Pixel Miniaturization via Eutectic Self-Assembly
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Solution Overview
Problem
Conventional LED display assembly methods struggle with miniaturization of pixels for personal and household applications, leading to inefficiencies and increased costs due to the inability to integrate hetero LED devices, switching devices, and driving devices on a single substrate.
Innovation Solution
The development of an active matrix LED display apparatus and fabrication method that involves forming a buffer layer, switching and driving transistor active layers, insulating layers, and eutectic layers on a substrate, allowing for the assembly of LED blocks through fluidic self-assembly processes to create miniaturized pixels with high electron mobility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional LED display assembly methods are used, then assembly is simpler with separate modules, but pixel miniaturization is difficult and cost increases
Solution Approach 1:
The patent merges LED devices, switching devices, and driving devices onto a single substrate to form integrated pixel structures. This consolidation enables pixel miniaturization by eliminating the need for separate module assembly, directly resolving the contradiction between small pixel size and assembly complexity.
Solution Approach 2:
The patent segments the display into multiple color element units (red, green, blue) that can be independently formed and then assembled. This segmentation allows for standardized miniaturized pixel structures while simplifying the overall assembly process through modular integration on a single substrate.
2Area of moving object
If hetero LED devices are integrated on a single substrate, then pixel miniaturization is achieved, but fabrication process becomes more complex
Solution Approach 1:
The patent forms buffer layers, transistor active layers, and insulating layers in advance before assembling the final pixel structure. This preliminary preparation of substrate components simplifies the overall fabrication process by organizing complex steps into manageable sequences, enabling miniaturization without proportionally increasing fabrication difficulty.
Solution Approach 2:
The patent uses buffer layers and insulating layers as intermediary structures that facilitate the integration of hetero LED devices on a single substrate. These intermediary layers mediate between different device components, enabling miniaturized pixel formation while managing fabrication complexity through standardized intermediate steps.
3Manufacturing precision
If miniaturized pixels are produced, then display resolution improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the physical and chemical parameters of materials (buffer layers, active layers, insulating layers) to enable precise formation of miniaturized pixels. By optimizing material parameters such as thickness, composition, and deposition conditions, the patent achieves high manufacturing precision for small pixels while maintaining production efficiency through standardized material processing.
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
Enables the miniaturization of pixels, facilitating the production of high-luminance, low-power consumption AM-LED displays with superior optical properties suitable for personal and household applications, while reducing assembly complexity and cost.
Implementation Method 1
a cathode eutectic layer and an anode eutectic layer which are formed separately from each other and are electrically connected to a cathode line and an anode contact layer, respectively
Implementation Method 2
assembled into the LED block receptor through electrical connections of the cathode eutectic layer and the anode eutectic layer to a cathode electrode and an anode electrode of the LED block, respectively
Implementation Method 3
an LED block of the color element unit assembled into the LED block receptor through electrical connections of the cathode eutectic layer and the anode eutectic layer to a cathode electrode and an anode electrode of the LED block, respectively
Data Source
AI summary
An active matrix LED display apparatus and a fabrication method thereof are provided. The active matrix LED display apparatus enables to miniaturize pixel by a formation of wiring on bottom layer and an assembly of each block through each eutectic layer into each transistor block receptor and/or each LED block receptor formed according to each color element unit, and to be embodied with high luminance, low power consumption, high reliability and superior optical property by assembling a transistor block having high electron mobility. And the fabricating method of the present invention enables to make efficiently an AM-LED display apparatus at room temperature in a short time by using different shapes of receptor and block depending on the function of a transistor and/or on the color of an LED.