Double Color Micro LED Panel with Non-Metallic Bonding
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Solution Overview
Problem
Miniaturization and portability requirements in LED panels lead to reduced pixel size and light output, increased light crosstalk, and difficulties in aligning and fabricating multi-color light emitting regions, resulting in decreased alignment accuracy, yield, and increased costs.
Innovation Solution
A double color micro LED display panel with a substrate, bonding layers, light emitting layers, and barrier components, where the barrier components block light emission between pixels, and the bonding layers are made of non-metallic materials to enhance light output and resolution, and include reflective and optical isolation structures to improve display efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the pixel size is decreased to achieve high resolution, then the resolution is improved, but the light output area is decreased and light output rate is reduced
Solution Approach 1:
The patent converts the harmful light crosstalk between adjacent pixels into a beneficial effect by using reflective structures. The reflective structures reflect light that would otherwise be lost or cause crosstalk back toward the viewing direction, thereby converting the harmful scattering into useful light output enhancement without increasing pixel size
Solution Approach 2:
The patent applies different material properties to different regions: metallic bonding layers in certain areas for electrical connection, and non-metallic bonding layers in other areas for optical transparency. This local differentiation allows simultaneous achievement of electrical functionality and optical performance in the miniaturized pixel structure
2Measurement precision
If the distance among pixels is decreased to achieve high resolution, then the resolution is improved, but light crosstalk between pixels increases and display efficiency decreases
Solution Approach 1:
The patent extracts and removes the harmful light crosstalk by introducing barrier components and reflective structures that selectively block or redirect light between pixels. These structures are positioned to intercept crosstalk light paths without interfering with the desired light output from each pixel
Solution Approach 2:
The patent introduces intermediary structures (barrier components and reflective structures) between adjacent pixels that mediate the light interaction. These intermediaries prevent direct light transmission between pixels, thereby eliminating crosstalk while maintaining the reduced pixel pitch required for high resolution
3Adaptability or versatility
If multiple light emitting regions are integrated in a pixel to achieve multi-color emission, then the color capability is improved, but the aligning and transferring processes become complex and alignment accuracy decreases
Solution Approach 1:
The patent merges multiple light emitting regions (red, green, blue LEDs) within a single pixel structure, allowing them to be controlled as one unit. This combining approach simplifies the alignment process compared to separate pixel structures, as the multiple color elements are integrated into a unified pixel architecture with shared bonding and control structures
Solution Approach 2:
The patent changes the material parameter of bonding layers from metallic to non-metallic in specific regions. This parameter change enables optical transparency where needed while maintaining electrical connectivity elsewhere, simplifying the fabrication process for multi-color pixels by reducing the number of different material types and processing steps required
4Weight of moving object
If the size of LED panel is limited for portability, then the portability is improved, but the light output area of each pixel is decreased
Solution Approach 1:
The patent converts the harmful effect of limited light output area (due to miniaturization) into a benefit by using reflective structures to redirect and concentrate the limited light from each small pixel. The reflective structures bounce light that would otherwise be lost toward the viewing direction, effectively amplifying the light output from the reduced pixel area
Solution Approach 2:
The patent addresses the two-dimensional limitation of pixel size by introducing vertical dimensionality through reflective structures and multi-layer configurations. This vertical arrangement allows light to be redirected and multiplied in three-dimensional space, compensating for the reduced horizontal pixel area while maintaining panel compactness
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
The solution effectively increases light output rate and display efficiency by blocking light crosstalk and improving resolution, while simplifying the fabrication process and reducing costs through the use of transparent bonding layers and reflective structures.
Implementation Method 1
The plurality of barrier components are respectively located between the pixels for blocking a light emitted from one of the pixels to the other of the pixels
Implementation Method 2
The barrier component can be a reflective structure to increase the light output rate, which improves the display efficiency
Implementation Method 3
The barrier component also can be an optical isolation structure to increase the resolution
Data Source
AI summary
The present invention discloses a double color micro LED display panel including a plurality of pixels and a plurality of barrier components. Each of the pixels includes a substrate, a first bonding layer configured on the substrate, a first light emitting layer configured on the first bonding layer and emitting a first light, a second bonding layer configured on the first light emitting layer and a second light emitting layer configured on the second bonding layer and emitting a second light. The wavelength of the second light is different from that of the first light. The barrier components respectively located between the pixels for blocking a light emitted from one of the pixels to the other of the pixels. Wherein, the material of the second bonding layer is a non-metallic material.