Micro-LED Display Panel Integration for Precise Pixel Alignment

The patent merges the micro light-emitting diode manufacturing process with the display panel manufacturing process by forming both structures simultaneously on the same substrate. The active layer is formed to define the micro light-emitting diode regions, while the semiconductor layer is formed in the same process sequence, eliminating the need for separate substrate manufacturing and transfer operations. This integration directly reduces process complexity while maintaining manufacturing ease.

The patent combines the formation of the active layer (defining micro light-emitting diode positions) and the semiconductor layer into a single integrated process. Both layers are formed on the same substrate in sequence, ensuring precise spatial alignment between the light-emitting structures and the transistor elements. This eliminates alignment errors that would occur during separate substrate transfer operations.

The patent forms the active layer first to precisely define the positions and dimensions of the micro light-emitting diodes at the intended resolution. Subsequently, the semiconductor layer is formed in registration with this pre-established active layer pattern. This preliminary action of defining the light-emitting structure positions before forming the transistor elements ensures that even at high pixel densities with reduced dimensions, precise alignment is maintained throughout the manufacturing process.