Micro-LED Display Alignment Structure for Constant Pixel Spacing
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Solution Overview
Problem
The high cost and low productivity of manufacturing light emitting display devices using micro light emitting diodes (LEDs) due to the expensive semiconductor substrates required for crystallizing inorganic materials like GaN, and the difficulty in accurately transplanting LEDs onto the display device substrate while maintaining a constant distance between them.
Innovation Solution
A display device design that includes a substrate with structures to maintain a constant distance between LED elements, allowing for precise arrangement and minimizing the bezel area, along with a method of using alignment keys to accurately position micro light emitting elements during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If micro light emitting diodes (LEDs) are used as light emitting elements, then high luminance and high reliability are achieved, but manufacturing cost increases and productivity decreases
Solution Approach 1:
The patent divides the LED array into multiple groups, with each group containing multiple LEDs. This segmentation allows for parallel processing during manufacturing, where entire groups can be handled simultaneously rather than individual LEDs, thereby improving productivity while maintaining the high reliability of LED technology.
Solution Approach 2:
The patent implements preliminary positioning structures on the substrate before LED mounting. These structures pre-establish the exact locations and orientations where LED groups will be placed, enabling faster and more accurate assembly. This preliminary preparation reduces the time and complexity of the transplanting process, improving productivity without compromising LED placement precision.
2Illumination intensity
If micro light emitting diodes (LEDs) are used as light emitting elements, then high luminance is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple LEDs into groups that are treated as single units during manufacturing. By merging the handling and positioning of multiple LEDs into a unified process, the complexity and cost of manufacturing are reduced. This approach maintains the high luminance output of multiple LEDs while simplifying the manufacturing process through standardized group-based assembly.
3Manufacturing precision
If alignment structures are added to maintain constant distance between LED elements, then positioning precision is improved, but device complexity increases
Solution Approach 1:
The alignment structures serve multiple functions: they provide positioning references for LED groups, maintain constant distances between LEDs, and facilitate automated assembly processes. By making these structures multi-functional, the patent achieves high positioning precision without proportionally increasing device complexity, as the same structures perform several critical roles in the manufacturing and assembly process.
Data Source
AI summary
A display device is disclosed. The display device includes a substrate having a plurality of pixels, wherein each of the plurality of pixels includes at least one light emitting chip, and a structure on one side of at least one of the plurality of pixels. A base material of the light emitting chip is the same as a base material of the structure.