Stacked Micro LED Pitch Variation for Manufacturing Efficiency
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Solution Overview
Problem
The manufacturing time for micro LED displays is prolonged due to the need for a large number of individually arranged µLEDs, which also increases the risk of defective products and manufacturing costs.
Innovation Solution
A self-luminous body for a display apparatus is designed with stacks of integrated self-luminous elements, where each stack includes multiple elements emitting the same color, arranged at different pitches to reduce the number of individual placements required, allowing for collective arrangement on a backplane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large number of µLEDs are individually arranged to form a display, then the display resolution and quality are improved, but the manufacturing time and complexity increase significantly
Solution Approach 1:
The patent divides the display into multiple subpixels (e.g., red, green, blue subpixels) that can be independently arranged and manufactured. Each subpixel type can be produced separately and then assembled, reducing the complexity of manufacturing the entire display at once while maintaining high resolution.
Solution Approach 2:
The patent combines multiple self-luminous elements of the same color into integrated units or arrays. By merging individual µLEDs of the same color into larger functional blocks, the patent reduces the number of separate placement operations required, thereby decreasing manufacturing time while preserving display quality.
2Manufacturing precision
If a large number of µLEDs are individually arranged to form a display, then the display quality is improved, but the manufacturing cost increases
Solution Approach 1:
By segmenting the display manufacturing into separate subpixel production lines, each specializing in a specific color or function, the patent enables more efficient mass production of individual components. This segmentation allows for optimized manufacturing processes for each subpixel type, reducing overall costs while maintaining high display quality.
Solution Approach 2:
The patent merges multiple µLEDs of the same color into integrated units that can be manufactured and tested as single components before final assembly. This merging reduces the total number of handling, placement, and quality check operations required, thereby reducing labor costs and manufacturing complexity while preserving display quality.
3Productivity
If multiple self-luminous elements are arranged at different pitches, then the number of individual placements is reduced, but the arrangement complexity increases
Solution Approach 1:
The patent applies different pitch arrangements in different regions of the display based on local requirements. Critical areas with higher resolution needs use finer pitches, while less critical areas use coarser pitches. This local differentiation reduces the overall number of placements required while maintaining necessary display quality in key regions.
Solution Approach 2:
The patent utilizes two-dimensional pitch variations, arranging self-luminous elements with different spacing in different directions (horizontal and vertical). This dimensional approach allows for optimized placement patterns that reduce total placement operations while maintaining display uniformity and quality through sophisticated geometric arrangements.
Data Source
AI summary
A time required to manufacture a self-luminous body for a display apparatus is shortened. A self-luminous body for a display apparatus includes a backplane and a plurality of stacks. The plurality of stacks are arranged on a backplane. Each stack includes a plurality of integrated self-luminous elements. The plurality of self-luminous elements in each stack include at least two self-luminous elements that are arranged at a first pitch and emit light of the same color. The plurality of stacks include a first stack and a second stack adjacent to each other. The self-luminous element of the first stack and the self-luminous element of the second stack that emits light of the same color as a color of light emitted by the self-luminous element of the first stack are arranged at a second pitch larger than the first pitch.