Micro LED Unit Pixel Structure for Easier High-Resolution Mounting
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Solution Overview
Problem
Micro LED displays face challenges in handling and mounting small micro LEDs due to their tiny size, making it difficult to arrange them on a display panel effectively.
Innovation Solution
A unit pixel structure comprising a transparent substrate, adhesive layer, step adjustment layer, and connection layers with a concave-convex pattern, which facilitates the arrangement and electrical connection of multiple light emitting devices, including red, green, and blue LEDs, on a circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro LEDs are made extremely small (200 μm or less, further 100 μm or less) to achieve high-resolution displays, then the display resolution is improved, but the ease of handling and mounting becomes significantly more difficult
Solution Approach 1:
A transfer substrate is introduced as an intermediary component. Micro LEDs are first mounted on the transfer substrate in a controlled environment, then the entire array is transferred to the final display panel. This mediator allows precise positioning and handling of extremely small micro LEDs without requiring direct manipulation at the final mounting location, thus resolving the contradiction between high resolution and ease of mounting.
2Manufacturing precision
If a large number of micro LEDs are arranged on a single substrate to achieve high-resolution displays, then the display quality is improved, but the device complexity and difficulty of assembly increase
Solution Approach 1:
The assembly process is segmented into distinct stages: micro LED fabrication on a first substrate, transfer substrate preparation, mounting micro LEDs on the transfer substrate, and final transfer to the display panel. This segmentation breaks down the complex task of arranging numerous micro LEDs into manageable steps, reducing overall assembly complexity while maintaining high display quality.
Solution Approach 2:
Micro LEDs are preliminarily arranged and fixed on the transfer substrate before final mounting on the display panel. This preliminary action allows for pre-verification of the micro LED array, error correction, and optimization of the arrangement pattern, thereby simplifying the final assembly process and reducing overall device complexity.
Data Source
AI summary
A display apparatus including a panel substrate and a pixel module disposed thereon, in which the pixel module includes a circuit board and light emitters arranged and aligned in a first direction and disposed on the circuit board, in which each light emitter includes a light emitting layer including a first and a second conductivity type semiconductor layer, and an active layer interposed therebetween, a first and a second connection layer electrically connected to the first and the second conductivity type semiconductor layer, respectively, and a step adjustment layer disposed between the circuit board and the light emitting layer and covering a region of the light emitting layer and including an opening region configured to provide an electrical contact region between the first connection layer and the first conductivity type semiconductor layer.