Micro LED Display Module with Light Transmissive Substrate
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Solution Overview
Problem
The low yield and high production cost of micro LED display modules due to the difficulty in transferring and wire bonding micro LEDs of different colors during the manufacturing process, which results in low product efficiency and high production costs.
Innovation Solution
A micro LED display module with a light transmissive substrate where micro LEDs are produced in an array form and disposed on a driver chip block, allowing each micro LED pixel to be driven individually, and a RGB color layer is used for full-color display, enabling easier transfer and production of high-resolution modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If micro LEDs of different colors are manufactured separately and attached in batches, then color accuracy and display quality are improved, but transfer difficulty and production cost increase
Solution Approach 1:
The patent combines multiple micro LEDs of different colors (red, green, blue) onto a single driver chip block, allowing them to be transferred together as one unit rather than separately. This merging approach maintains color accuracy while significantly reducing transfer difficulty and production complexity
Solution Approach 2:
The driver chip block is designed to universally drive multiple micro LEDs of different colors simultaneously. The single driver chip block can control and transfer various colored micro LEDs together, making the transfer process more efficient and reducing the need for separate handling of each color type
2Manufacturing precision
If micro LEDs are transferred individually, then precise positioning is achieved, but production efficiency and product yield decrease
Solution Approach 1:
Multiple micro LEDs are combined into an array structure on the driver chip block, enabling batch transfer while maintaining precise positioning. The array configuration allows all micro LEDs to be positioned accurately together, significantly improving production efficiency without sacrificing positioning accuracy
Solution Approach 2:
The micro LEDs are pre-arranged in an array configuration on the driver chip block before transfer. This preliminary arrangement ensures that precise positioning is already established, eliminating the need for individual positioning operations during the transfer process and thereby improving production efficiency
3Area of stationary object
If conventional LEDs are used for display, then large-sized panels are achieved, but resolution and power efficiency deteriorate
Solution Approach 1:
The display is segmented into multiple micro LEDs arranged in an array on the driver chip block. Each micro LED acts as an independent light-emitting pixel, enabling high resolution while maintaining large display area. The segmentation allows for precise control of each pixel, achieving both large size and high resolution simultaneously
4Ease of manufacture
If batch transfer of micro LEDs is performed, then production cost is reduced, but transfer difficulty and product yield worsen
Solution Approach 1:
Multiple micro LEDs are merged into a single array structure on the driver chip block, enabling batch transfer as one unit. This approach reduces production cost through batch processing while maintaining high product yield, as the array structure ensures all micro LEDs are transferred together with consistent positioning and alignment
Data Source
AI summary
A micro LED display module having a light transmissive substrate and a manufacturing method thereof are provided. The light transmissive substrate has good transmissivity with respect to the visible band. The micro LED display module comprises a driver chip block, a LED block, a circuit board and a color layer. The LED block is disposed in the driver chip block and has two semiconductor layers and a plurality of trenches. One of the two semiconductor layers is electrically connected to pixel electrodes and the other is electrically connected to the light transmissive substrate. The trenches define a plurality of micro LED pixels arranged in an array. Each micro LED pixel corresponds to one of the pixel electrodes. The circuit board is electrically connected to the driver chip block, the color layer is disposed in the light transmissive conductive layer, and one of the semiconductor layers has a common electrode.