Micro-LED Chip Layout With Color Conversion for High-Resolution Displays
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Solution Overview
Problem
Existing Mini/Micro LED display technologies face challenges in increasing resolution and color accuracy due to the need for multiple LED chips, each emitting a single color, which increases manufacturing complexity and can result in uneven brightness and reduced product yield.
Innovation Solution
A Mini/Micro LED chip design featuring multiple LEDs on a single chip with integrated semiconductor layers, color conversion patterns, and light shielding layers to enable multi-color display and reduce the number of transferred chips, along with a manufacturing method that includes forming LEDs on a substrate with a pixel defining layer and color conversion patterns to convert light into target colors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple single-color LED chips are used to achieve high resolution and color accuracy, then color accuracy is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple LED chips with different semiconductor patterns (first, second, and third semiconductor patterns emitting different colors) onto a single substrate to form one multi-color LED chip. This merging approach replaces the need for multiple separate single-color chips, thereby improving color accuracy while reducing device complexity and manufacturing complexity.
Solution Approach 2:
The single LED chip substrate is designed to perform multiple functions by integrating different semiconductor patterns that emit different colors (red, green, blue). This multi-functional design allows one chip to replace multiple specialized single-color chips, reducing the overall number of components and simplifying the manufacturing process while maintaining high color accuracy.
2Measurement precision
If multiple single-color LED chips are used to achieve high resolution, then color accuracy is improved, but the number of chips to be transferred increases
Solution Approach 1:
By merging multiple LED chips onto a single substrate, the patent reduces the total number of chips that need to be transferred during manufacturing. One multi-color chip replaces multiple single-color chips, directly decreasing the transfer count and improving productivity and product yield while maintaining the color accuracy benefits of having multiple color-emitting elements.
3Measurement precision
If multiple single-color LED chips are used, then color accuracy is improved, but brightness uniformity deteriorates
Solution Approach 1:
The patent applies local quality by positioning different semiconductor patterns (emitting different colors) in specific regions of the substrate and using pixel defining layers with precisely controlled openings. Each region's light emission is locally controlled to ensure that the combined output from all regions achieves uniform brightness across the entire display, while maintaining the color accuracy benefits of having multiple color-emitting semiconductor patterns.
4Measurement precision
If multiple single-color LED chips are used to achieve high resolution, then color accuracy is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple LED chip functions into a single integrated chip structure, where first, second, and third semiconductor patterns are fabricated on one substrate. This consolidation reduces the number of discrete components and interconnections required, thereby decreasing device complexity while maintaining the color accuracy advantages of having multiple color-emitting elements.
Solution Approach 2:
The single LED chip substrate is designed to perform multiple color-emitting functions simultaneously through different semiconductor patterns. This multi-functional design eliminates the need for separate single-color chips and their associated mounting, wiring, and control structures, thereby reducing overall device complexity while achieving high color accuracy.
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 design allows for a more efficient manufacturing process with improved color accuracy and reduced complexity, enabling higher resolution displays with even brightness and increased product yield by integrating multiple LEDs and color conversion capabilities into a single chip.
Implementation Method 1
a color conversion pattern within at least two of the pixel openings, the color conversion pattern being configured to convert light of a first color emitted by the light emission pattern into light of a target color other than the first color
Implementation Method 2
a first light shielding layer between the pixel defining layer and the substrate in a vertical direction, and between adjacent ones of the LEDs when viewed in a plan view, the first light shielding layer being configured to shield light emitted by at least one of the adjacent LEDs and refracted by the substrate
Data Source
AI summary
A LED chip, including: substrate; LEDs on side of the substrate, each including first semiconductor pattern, light emission pattern, second semiconductor pattern sequentially stacked, the first semiconductor patterns of at least two LEDs being formed as single piece to constitute first semiconductor layer; at least one first electrode on side of first semiconductor layer away from the substrate and electrically coupled to first semiconductor layer; second electrodes on side of the second semiconductor patterns away from the substrate, each being electrically coupled to second semiconductor pattern of corresponding LED; pixel defining layer on side of the substrate away from LED, and having pixel openings in one-to-one correspondence with LEDs; and a color conversion pattern within at least two pixel openings, and converting light of first color emitted by the light emission pattern into light of target color other than the first color. The LED chip is Mini-LED or Micro-LED chip.