Micro LED Display Package Layout With Tapered Circuit Holes
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Solution Overview
Problem
Micro LED displays face challenges in accurate mass transfer of micro LEDs onto circuit boards and in enhancing luminous efficiency, with existing methods being mechanical and prone to placement errors affecting performance.
Innovation Solution
A display device design featuring a first substrate with a circuit structure having holes, where light-emitting element packages with overlapping LEDs emit light towards the substrate, with the hole width near the substrate being greater than near the package substrate, enhancing light reflection and brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mass transfer technique is used to transfer micro LEDs onto circuit board, then productivity is improved, but manufacturing precision deteriorates due to mechanical placement errors
Solution Approach 1:
The patent replaces the mechanical mass transfer technique with a self-aligned structure. The tapered hole design allows micro LEDs to be positioned accurately through geometric constraint rather than mechanical placement, eliminating the trade-off between transfer speed and placement precision.
Solution Approach 2:
The circuit structure is pre-formed with tapered holes that guide and constrain micro LED placement. This preliminary geometric preparation ensures that when micro LEDs are transferred, they automatically align to the correct positions without requiring high-precision mechanical positioning during the transfer process.
2Device complexity
If conventional flat circuit structure is used, then device complexity is reduced, but illumination intensity deteriorates due to poor light extraction
Solution Approach 1:
The patent introduces asymmetric tapered holes into the otherwise simple circuit structure. The non-uniform cross-section of the holes creates favorable light extraction geometry without significantly complicating the overall device design, thereby improving brightness while maintaining structural simplicity.
Solution Approach 2:
The patent transitions from a two-dimensional flat circuit structure to a three-dimensional tapered hole structure. This vertical dimensionality addition creates light-guiding pathways that improve light extraction efficiency and display brightness without adding lateral complexity to the device layout.
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 design improves the accuracy of micro LED placement and luminous efficiency, resulting in higher brightness and yield of the display device by better reflecting light towards the substrate.
Implementation Method 1
at least one light-emitting element. The light-emitting element is located between the second substrate and the first substrate, emits light toward the first substrate
Implementation Method 2
The width of the corresponding hole near the first substrate is greater than the width of the corresponding hole near the second substrate... better reflecting light towards the substrate
Data Source
AI summary
A display device includes a first substrate, a first circuit structure, and light-emitting element package structures. The first circuit structure is located above the first substrate, and the first circuit structure has holes. Light-emitting element package structures are located above the first circuit structure. Each light-emitting element package structure includes a second substrate and at least one light-emitting element. The light emitting element is located between the second substrate and the first substrate, emitting toward the first circuit substrate, and overlapping with corresponding hole of the first circuit structure. The width of the corresponding hole near the first substrate is greater than the width of the corresponding hole near the second substrate.