Micro LED Pixel Layout With Overlapped Mesas and No External Panel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional micro LED pixels have a large external panel that increases their dimensions, making it challenging to reduce the volume and increase the light emitting area effectively.
Innovation Solution
The micro LED pixel design features three light emitting mesas that are staggered and spaced apart vertically, with at least parts of two mesas overlapping, eliminating the need for an external panel by integrating electrodes and conductive layers within the pixel structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If micro LED mesas are arranged side by side horizontally, then the light emitting area is increased, but the cross-sectional dimensions of the micro LED pixel become larger
Solution Approach 1:
The patent transitions from a horizontal side-by-side arrangement of micro LED mesas to a vertical stacked arrangement along the same cross-section. By utilizing the vertical dimension (z-axis) instead of expanding horizontally (x-y plane), the light emitting area is increased while the cross-sectional dimensions remain compact. Multiple light emitting mesas are stacked vertically with at least partial overlap in their horizontal projections, allowing more emitting surfaces within the same footprint.
2Ease of manufacture
If an external panel is used to form electrodes for micro LED mesas, then the electrode formation is simplified, but the overall dimensions of the micro LED pixel increase
Solution Approach 1:
The patent integrates the electrode formation process directly within the micro LED pixel structure itself, merging the electrode layer with the light emitting mesa layers. The electrodes are formed between and around the light emitting mesas in the vertical stack, eliminating the need for a separate external panel. This integration reduces the overall pixel dimensions while maintaining manufacturability through standard semiconductor processing techniques.
Solution Approach 2:
The electrode structures are nested within the vertical stack of light emitting mesas, with electrodes positioned between adjacent mesas and extending along the vertical dimension. This nesting approach allows electrodes to be formed within the compact vertical architecture rather than requiring external panel space, reducing the horizontal footprint while maintaining electrical connectivity.
Data Source
AI summary
A micro LED pixel includes three light emitting mesas including a first light emitting mesa, a second light emitting mesa, and a third light emitting mesa. At least parts of at least two light emitting mesas of the three light emitting mesas are overlapped, and at least part of the second light emitting mesa does not cover the first light emitting mesa or at least part of the third light emitting mesa does not cover the first light emitting mesa or the second light emitting mesa, the first light emitting mesa, the second light emitting mesa, and the third light emitting mesa do not contact with each other.