Micro-LED Display Panel Layout for High-PPI Color Separation
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Solution Overview
Problem
Current micro-LED display panel technologies face limitations in increasing pixels per inch (PPI) due to the process of transferring individual red, green, and blue micro-LED chips, which restricts the ability to reduce pixel size and pitch, making it difficult to enhance color reproducibility and resolution.
Innovation Solution
The display panel employs spatially separated subpixel arrays for red, green, and blue micro-LED elements, each with a color conversion layer using quantum dots, allowing for independent transfer and patterning of subpixels, thereby reducing subpixel size and pitch, and utilizing a combining optical system to form a full-color image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual red, green, and blue micro-LED chips are transferred to increase PPI, then pixel density is improved, but the process complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The display panel is divided into three separate subpixel arrays (first, second, and third subpixel arrays) corresponding to red, green, and blue micro-LED elements, which are spatially separated and arranged side by side on the substrate. This segmentation allows for simplified manufacturing of monochromatic micro-LED arrays compared to transferring individual multi-color chips.
Solution Approach 2:
Instead of increasing PPI by reducing the size of individual RGB subpixel groups, the patent arranges monochromatic subpixel arrays side by side in the spatial dimension. The combining optical system then overlaps these separated arrays optically to create the perception of high-density RGB pixels, effectively increasing PPI through spatial arrangement rather than miniaturization.
2Measurement precision
If subpixel size is reduced to increase PPI, then pixel density is improved, but color separation and conversion efficiency deteriorate
Solution Approach 1:
The patent separates red, green, and blue micro-LED elements into distinct subpixel arrays with different spatial regions on the substrate. This physical separation prevents optical crosstalk between color channels, ensuring excellent color separation even when subpixels are small. Each monochromatic array can be optimized independently for its wavelength.
Solution Approach 2:
The patent introduces a combining optical system as an intermediary between the separated monochromatic subpixel arrays and the viewer's eye. This optical system overlaps the spatially separated red, green, and blue light fields to create the perception of co-located RGB pixels, maintaining color separation efficiency while achieving high PPI.
3Reliability
If individual micro-LED chips are transferred to improve color reproducibility, then color accuracy is improved, but manufacturing productivity decreases
Solution Approach 1:
The patent divides the display into three separate monochromatic subpixel arrays, each containing only red, green, or blue micro-LED elements. This segmentation allows for specialized manufacturing processes optimized for each color wavelength, improving color reproducibility. Each monochromatic array can be fabricated using wavelength-specific materials and processes.
Solution Approach 2:
The patent merges three separately manufactured monochromatic micro-LED arrays into a single display panel structure. By producing red, green, and blue arrays separately and then integrating them on the substrate, the manufacturing process achieves both high color reproducibility (through specialized monochromatic fabrication) and improved productivity (by avoiding the complexity of transferring individual multi-color chips).
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 enables increased PPI by reducing subpixel sizes and pitches, improving color separation and conversion efficiency, and facilitating the manufacture of high-resolution micro-LED displays for augmented and virtual reality applications.
Implementation Method 1
a first color conversion layer that absorbs a first excitation light emitted from the first micro-LED element and emits light of a first primary color wavelength
Data Source
AI summary
Disclosed are a display device and a display panel including a substrate, a first subpixel array including first subpixels arranged in a first region on the substrate, a second subpixel array including second subpixels arranged in a second region on the substrate, and a third subpixel array including third subpixels arranged in a third region on the substrate. The first region, the second region, and the third region are spatially separated and provided side by side on a same surface of the substrate. The first subpixels are grouped by a first primary color and are patterned as the first subpixel array in the first region. The second subpixels are grouped by a second primary color and are patterned as the second subpixel array in the second region. The third subpixels are grouped by a third primary color and patterned as the third subpixel array in the third region.