Micro LED Panel RGB Stacking for Precision-Limited Yield
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Solution Overview
Problem
Conventional micro LED display panels face manufacturing yield limitations due to the high precision required for arranging tiny red, green, and blue sub-pixels horizontally, which affects processing precision and yield.
Innovation Solution
The micro LED display panel design includes a stack of blue, green, and red LED layers where the green LED layer is positioned between the blue and red layers, with each sub-pixel spaced apart and non-overlapping, allowing light from lower layers to pass through transparent regions, enabling staggered sub-pixel arrangement and improved manufacturing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If red, green, and blue sub-pixels are arranged horizontally in conventional micro LED display panels, then the display can show full color, but the processing precision requirement becomes extremely high which limits manufacturing yield
Solution Approach 1:
The patent transitions from a two-dimensional horizontal arrangement of sub-pixels to a three-dimensional stacked arrangement where red, green, and blue sub-pixels are positioned at different vertical levels. This dimensional change allows sub-pixels to be spaced apart horizontally while maintaining color fidelity, thereby reducing processing precision requirements and improving manufacturing yield
2Measurement precision
If each sub-pixel is made tiny (less than 100 μm) to achieve high resolution, then the display resolution improves, but the processing precision requirement increases which limits manufacturing yield
Solution Approach 1:
By stacking sub-pixels vertically at different heights, the patent enables larger horizontal spacing between sub-pixels of the same color while maintaining small sub-pixel dimensions. This resolves the conflict between achieving high resolution through tiny sub-pixels and the manufacturing difficulty of precisely positioning them
Solution Approach 2:
The patent divides the display into multiple vertical layers, with each layer containing sub-pixels of a specific color. This segmentation allows independent optimization of each layer's sub-pixel spacing and positioning, reducing the overall processing precision burden while maintaining high display resolution
Data Source
AI summary
A micro LED display panel includes a blue LED layer, a green LED layer, and a red LED layer. The blue LED layer, the green LED layer, and the red LED layer are in a stacked formation. The blue, the green, and the red LED layers each include a plurality of micro LEDs spaced apart from each other. The composition of the layers is such that light emitted from all but the bottom layer is able to pass through transparent material in other layers before exiting the panel and being viewed.