Ultra-Thin Fin LED Pixel Structure for Alignment and Driving
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Solution Overview
Problem
The manufacturing of high-resolution micro-LED displays is hindered by high unit costs, high process defect rates, and low productivity due to the complexity of placing and aligning nano-LEDs in subpixels, with existing nanorod-type LEDs having inefficient light extraction areas and high surface defect issues.
Innovation Solution
A pixel structure using ultra-thin fin LED devices with a switching function that allows for the switching between alignment and driving electrodes, featuring a lower electrode with spaced-apart electrodes for magnetic alignment and light reflection, and an upper electrode for driving, along with a switch to manage voltage application for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If nanorod-type LEDs are used for high-resolution displays, then the light-emitting area is increased, but surface defects significantly reduce light-emitting efficiency
Solution Approach 1:
The patent changes the geometric parameters of the LED structure from nanorod-type to ultra-thin fin type, where the thickness is specifically controlled to be 10nm to 100nm. This parameter change maintains a large light-emitting area while reducing the impact of surface defects on efficiency by altering the dimension in which surface defects primarily affect performance
Solution Approach 2:
The ultra-thin fin LED device employs a composite structure comprising multiple layers including first and second conductive semiconductor layers, an active layer, and buffer layers with different material compositions. This composite structure allows optimization of each layer to mitigate surface defect effects while maintaining large light-emitting area
2Ease of operation
If separate alignment and driving electrode arrays are implemented, then the ultra-thin fin LED devices can be properly aligned and driven, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements a multi-functional electrode structure where the same electrode array serves both alignment and driving functions. The electrodes are designed to apply electric fields for alignment during manufacturing and subsequently provide driving signals for operation, eliminating the need for separate electrode arrays and reducing overall device complexity
Solution Approach 2:
The alignment and driving functions are merged into a single electrode system. The electrode structure is designed to perform both alignment of ultra-thin fin LED devices during fabrication and driving during operation, combining what would traditionally require separate electrode arrays into one integrated system
3Reliability
If nanorod-type LEDs are used with small light-emitting area, then fewer LEDs are needed per display, but a large number of LEDs must be mounted to achieve desired efficiency, increasing productivity challenges
Solution Approach 1:
The patent changes the LED geometry from nanorod to ultra-thin fin configuration with thickness of 10nm to 100nm, which provides a larger light-emitting area per device. This allows each LED to contribute more to the overall display efficiency, reducing the total number of LEDs required and simplifying the mounting process to improve productivity
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 solution enables efficient alignment and driving of ultra-thin fin LED devices, improving light-emitting efficiency, reducing surface defects, and lowering manufacturing costs while enhancing image quality and lifespan.
Implementation Method 1
an alignment electrode to align the ultra-thin devices in the pixel, and a driving electrode is needed to operate the aligned ultra-thin devices in the pixel. In this case, the alignment electrode is located at the bottom to form a horizontal electric field, thereby aligning the ultra-thin devices located at the top according to the horizontal electric field.
Implementation Method 2
a reflective layer to reflect the light emitted from the plurality of ultra-thin fin LED devices in each subpixel space toward an upper portion which is a front surface
Data Source
AI summary
A pixel structure and driving method of an ultra-thin device display with alignment and driving electrode switching functions.