Micro LED Display Partitions for Maskless Color Patterning
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Solution Overview
Problem
The manufacturing of high-resolution display apparatuses using micro light emitting diodes (LEDs) faces challenges in achieving high process yields and reducing costs, particularly in patterning color conversion layers and color filters without using masks, while minimizing residue and ensuring efficient light extraction.
Innovation Solution
A display apparatus design featuring a semiconductor layer with partitions and opening areas, where color conversion layers and color filters are formed without masks, using photoresist and quantum dots or phosphors, and a light extraction pattern is integrated to enhance light emission efficiency, allowing for independent driving of active layers and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mask-based patterning is used for color conversion layers and color filters, then manufacturing precision can be maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and removes the mask from the patterning process. Instead of using physical masks to define patterns, the invention uses direct self-aligned patterning methods where the pattern is formed by the structural arrangement of components themselves, eliminating the need for separate mask layers and mask alignment processes.
Solution Approach 2:
The structure serves its own patterning function. The semiconductor layer with its inherent structural features (such as pillar arrangements or trench patterns) automatically defines the pattern locations for color conversion layers and color filters without requiring external patterning tools, making the structure self-patterning.
2Reliability
If conventional manufacturing processes are used, then process stability can be maintained, but process yield and productivity decrease due to multiple complex steps
Solution Approach 1:
The patent merges multiple separate manufacturing steps into a more integrated process. By combining the formation of semiconductor structures with the patterning of color conversion layers and color filters into a unified self-aligned process, the number of discrete manufacturing steps is reduced, improving both yield and productivity while maintaining stability.
Solution Approach 2:
The semiconductor layer structure is prepared in advance with pre-defined pattern features (such as pillars or trenches) that will later serve as alignment references. This preliminary structuring enables subsequent layers to be automatically positioned correctly without requiring complex real-time alignment procedures.
3Manufacturing precision
If high-resolution display is achieved using micro LEDs, then display quality improves, but manufacturing difficulty and cost increase due to high-level transfer technology requirements
Solution Approach 1:
The patent replaces complex mechanical transfer processes with a more straightforward structural formation approach. Instead of mechanically transferring pre-fabricated micro LED chips onto a substrate using sophisticated pick-and-place or transfer printing techniques, the invention forms the micro LED structures directly in their final positions through semiconductor processing methods, eliminating the need for high-level transfer technology.
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 approach results in a high-resolution display with improved process yields, reduced manufacturing costs, and minimal residue, enabling efficient light extraction and enhanced color purity, potentially achieving resolutions of 5000 pixels per inch or more.
Implementation Method 1
a plurality of active layers provided opposite to the plurality of opening areas on the second surface of the first semiconductor layer
Implementation Method 2
a plurality of color conversion layers provided in the plurality of opening areas on the first surface of the first semiconductor layer
Data Source
AI summary
Provided is a display apparatus including a first semiconductor layer having a first surface and a second surface opposite to each other, a plurality of partitions protruding from the first surface, and a plurality of opening areas between the plurality of partitions, a plurality of active layers provided opposite to the plurality of opening areas on the second surface of the first semiconductor layer, a plurality of second semiconductor layers respectively provided on the plurality of active layers opposite to the first semiconductor layer, a separation film provided between two adjacent active layers among the plurality of active layers and between two adjacent second semiconductor layers among the plurality of second semiconductor layers, and a plurality of color conversion layers provided in the plurality of opening areas on the first surface of the first semiconductor layer.