Vertically Stacked Micro LED Pixel for Large Emitting Area
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Solution Overview
Problem
Traditional micro LED pixel structures face challenges in reducing dimensions while maintaining a large light emitting area, often requiring external panels that increase pixel size.
Innovation Solution
The micro LED pixel design features three light emitting mesas staggered vertically, with at least part of the top mesa covering the middle one, and all mesas having separate electrodes and bottom pads without external connections, allowing for reduced cross-sectional dimensions.
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 maintained, but the pixel dimensions increase
Solution Approach 1:
The patent transitions from horizontal side-by-side arrangement of micro LED mesas to a vertical stacked arrangement along the Z-axis. This dimensional change allows multiple light emitting mesas to be positioned at different heights (first mesa at bottom, second mesa in middle, third mesa at top), enabling the light emitting areas to overlap in the vertical direction while reducing the horizontal footprint of the pixel.
Solution Approach 2:
The patent implements a nested configuration where the light emitting area of the third mesa fully covers the second mesa, and the second mesa covers part of the first mesa. This nesting arrangement allows the mesas to be vertically stacked with overlapping projections, maximizing space utilization and reducing the overall pixel dimension while maintaining sufficient light emitting area.
2Length of stationary object
If external panels are used to connect electrodes for vertically stacked mesas, then the pixel dimension is reduced, but the device complexity increases
Solution Approach 1:
The patent merges the electrode connection functions within the pixel structure itself. The first and second bottom pads are positioned on the same plane and can be connected through conductive structures within the pixel, eliminating the need for external panels. This integration reduces device complexity while maintaining the reduced pixel dimension advantage.
Solution Approach 2:
The pixel structure is designed to be self-sufficient with all necessary electrode connections implemented within the pixel itself. The bottom pads and conductive layers are arranged to provide internal connectivity without requiring external intervention or additional external panel structures, making the pixel a complete, self-contained unit.
3Length of stationary object
If vertically stacked mesas are arranged with full overlap, then the pixel dimension is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies different overlap configurations to different mesas based on their specific functions and positions. The third mesa has its light emitting area fully covering the second mesa, while the second mesa covers only part of the first mesa. This localized differentiation in overlap arrangements allows for optimized manufacturing tolerances at each level rather than requiring uniform high precision throughout.
Solution Approach 2:
The patent implements partial overlap between the second and first mesas, rather than requiring complete overlap of all mesas. This partial overlap approach reduces the stringency of manufacturing precision requirements while still achieving the goal of reducing pixel dimensions through vertical stacking.
Data Source
AI summary
A micro LED pixel includes a first light emitting mesa; a second light emitting mesa provided above the first light emitting mesa; and a third light emitting mesa provided above the second light emitting mesa; wherein at least part of the third light emitting mesa fully covers the second light emitting mesa; and the first light emitting mesa, the second light emitting mesa and the third light emitting mesa do not contact each other.