Micro-LED Module Partition Layout for Seamless Pixel Alignment
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Solution Overview
Problem
Existing display devices using micro-LEDs face challenges in efficiently transferring and aligning micro-LEDs, leading to issues with pixel alignment tolerance and visual seams between LED modules.
Innovation Solution
The proposed display device includes a circuit substrate with a driving circuit, an LED cell array comprising multiple LED modules with insulator coupling, a gap-fill layer, partitions defining light emitting windows, and at least one color conversion layer. Each LED cell has an active layer and conductivity-type semiconductor layers connected to electrodes, with a partition structure and color conversion layers optimizing light emission and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If micro-LEDs are transferred to form LED modules, then the display device can achieve high luminance and compact size, but alignment tolerance issues and visual seams between modules occur
Solution Approach 1:
The patent divides the LED cell array into multiple LED modules, where each module contains a specific number of LED cells (e.g., 2x2 arrangement). This segmentation allows independent transfer and alignment of modules rather than individual cells, reducing cumulative alignment errors and simplifying the transfer process while maintaining high luminance output from the assembled modules.
2Manufacturing precision
If partitions are added to define light emitting windows, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The patent integrates the partition structure with the LED module assembly process. The partitions are formed as part of the module structure itself, combining the functions of light emission definition and structural support. This merging approach achieves precise alignment without requiring separate complex alignment mechanisms, as the partitions naturally define the light emitting windows during the module assembly process.
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 configuration simplifies the micro-LED transfer process, reduces alignment deviations, and ensures consistent gaps between sub-pixels, resulting in improved luminous efficiency and a seamless display without visual seams.
Implementation Method 1
at least one color conversion layer disposed in at least a portion of the plurality of light emitting windows
Data Source
AI summary
A display device includes a circuit substrate including a driving circuit; an LED cell array disposed on the circuit substrate, and including a plurality of LED modules, each of the plurality of LED modules including at least two LED cells, from among a plurality of LED cells of the LED cell array, and an insulator coupling the at least two LED cells to each other; a gap-fill layer filling a gap between the plurality of LED modules; a partition disposed on the LED cell array, and defining a plurality of light emitting windows disposed in regions corresponding to the plurality of LED cells, respectively; and at least one color conversion layer disposed in at least a portion of the plurality of light emitting windows.