Layered LED Pixel Structure to Reduce Display Light Loss
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Solution Overview
Problem
Existing display apparatuses using LEDs as pixels lack a simplified manufacturing process, leading to inefficiencies and potential light loss due to overlapping LED cells.
Innovation Solution
A display apparatus design featuring a pixel array with LED cells arranged in multiple layers, including a first group of LED cells on one level and a second group on a lower level, connected by common electrodes and individual electrodes, allowing for a simplified manufacturing process and reduced light loss through optimized optical paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If LED cells are arranged in overlapping configurations, then device complexity is reduced, but light loss increases
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement of LED cells to a three-dimensional stacked configuration. Multiple LED cells are arranged vertically at different heights, allowing them to overlap in the horizontal plane while maintaining separation in the vertical dimension. This dimensional change enables simplified manufacturing through standardized stacking processes while preventing light loss by ensuring each LED cell has its own optical path to the display surface.
2Manufacturing precision
If multiple LED cells are placed at the same level, then manufacturing precision is improved, but light loss occurs due to overlapping
Solution Approach 1:
The invention introduces vertical stacking of LED cells at different heights (first level, second level, third level) to resolve the conflict between manufacturing precision and light loss. By arranging LED cells in the vertical dimension rather than forcing them into a single horizontal plane, the system maintains precise alignment within each level while preventing horizontal overlap that causes light loss.
Solution Approach 2:
The patent implements a nested arrangement where LED cells at different levels are vertically stacked, with each level containing LED cells that are horizontally aligned but vertically separated. This nesting in the vertical dimension allows precise manufacturing of each level while the overall structure prevents light loss through the vertical stratification of optical paths.
3Device complexity
If LED cells are arranged in a single layer, then device complexity is reduced, but productivity decreases due to manufacturing inefficiencies
Solution Approach 1:
The patent segments the LED cell array into multiple independent layers (first, second, and third levels), where each layer can be manufactured and assembled separately. This segmentation enables parallel manufacturing processes, improves overall manufacturing yield by isolating defects to specific layers, and maintains relatively simple individual layer structures that can be produced using standardized processes.
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 design enables high-efficiency display apparatuses with minimized light loss and improved manufacturing yield by integrating LED cells in a layered structure, enhancing brightness and reducing manufacturing complexity.
Implementation Method 1
Semiconductor light-emitting diodes (LEDs) may be used not only as light sources for lighting devices, but also as light sources for various electronic products. In particular, LEDs may be widely used as light sources for various display apparatuses
Data Source
AI summary
A display apparatus includes a first semiconductor layer having a first LED cell and a second LED cell; first and second electrode pads respectively electrically connected to the first and second LED cells; a first common electrode pad electrically connected to the first semiconductor layer; a first insulating layer between the first passivation layer and a circuit board; a second semiconductor layer between the first insulating layer and the circuit board and including a third LED cell; a third electrode pad electrically connected to the third LED cell; individual electrodes electrically connecting the first to third electrode pads and a driving circuit; and a common electrode electrically connecting the first common electrode pad and the driving circuit.