Micro-LED Conductive Layer Stacking for Full-Color Display Yield
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Solution Overview
Problem
Existing display technologies face challenges in achieving full-color micro displays with reduced pixel sizes, as the mass transfer process for micro-light-emitting chips is complex and affects yield rates, particularly for green light conversion where quantum dot materials are used.
Innovation Solution
A display device and fabrication method that eliminates the need for mass transfer by using a control panel with multiple conductive layers of different thicknesses, where micro-light-emitting elements with different colors are independently stacked and etched to prevent overlap, allowing for a single-chip full-color micro display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mass transfer process is used to transfer micro-light-emitting chips to control panel, then full-color display can be achieved, but yield rate decreases and fabrication complexity increases
Solution Approach 1:
The patent merges multiple single-color micro-light-emitting chips (red, green, blue) into a single integrated full-color micro-display chip. This is achieved by stacking multiple epitaxial structure layers with different light-emitting colors on the same substrate, eliminating the need for separate mass transfer processes for each color chip. The integration directly improves yield rate by avoiding transfer losses while maintaining full-color display capability.
Solution Approach 2:
The patent transitions from a planar arrangement of separate color chips to a three-dimensional stacked structure. Multiple epitaxial layers are stacked vertically on the substrate, with each layer emitting a different color. This vertical stacking enables full-color display within a compact footprint while simplifying the fabrication process by eliminating complex mass transfer operations.
2Adaptability or versatility
If quantum dot materials are used for green light conversion, then full-color display is achieved, but conversion efficiency decreases and lifespan is reduced
Solution Approach 1:
The patent extracts and eliminates the quantum dot material component from the display structure. Instead of using quantum dots for green light conversion, the invention directly integrates a green light-emitting epitaxial layer that emits green light natively. This removal of quantum dot materials resolves the issues of low conversion efficiency and reduced lifespan while maintaining full-color display capability through direct emission from multiple epitaxial layers.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly improves the yield rate of display device fabrication, reduces transfer and repair costs, and enhances light-emitting efficiency and lifespan without relying on quantum dot color conversion technology.
Implementation Method 1
The first light-emitting layer emits light with a first color. The second light-emitting layer emits light with a second color which is different from the first color.
Implementation Method 2
The conductive layer is patterned to be etched to expose the control panel, wherein the conductive layer is etched and divided into a plurality of first conductive layers and a plurality of second conductive layers
Data Source
AI summary
A display device includes a control panel, a conductive layer, a first micro-light-emitting element and a second micro-light-emitting element. The conductive layer directly connects to the control panel. The conductive layer is divided into a first conductive layer with a first thickness and a second conductive layer with a second thickness. The second thickness is greater than the first thickness. The first micro-light emitting element is disposed on the first conductive layer. The first micro-light-emitting element has a first light-emitting layer emitting light with a first color. The second micro-light emitting element is disposed on the second conductive layer. The second micro-light-emitting element has a second light-emitting layer. The second light-emitting layer emits light with a second color that is different from the first color. The projections of the first micro-light-emitting element and the second micro-light-emitting element on the control panel do not overlap with each other.