MicroLED Pixel Layout Using Shape-Coded Alignment Keys
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Solution Overview
Problem
The challenge lies in manufacturing high-resolution display devices using semiconductor light-emitting devices, particularly in achieving accurate transfer and reliable assembly of microLEDs for large-area displays, as existing methods like pick & place and laser lift-off are inefficient and costly, especially when dealing with millions of devices.
Innovation Solution
A display device with a wiring substrate featuring pixel areas of varying arrangements and shapes for red, green, and blue semiconductor light-emitting devices, where some pixel areas serve as alignment keys during the transfer process, allowing for improved transfer accuracy and reliability by using the same devices as alignment tools, thereby eliminating the need for separate alignment keys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pick & place method is used to transfer microLEDs, then transfer of semiconductor light-emitting devices can be achieved, but manufacturing efficiency is low and cost is high
Solution Approach 1:
The microLEDs perform self-alignment through their inherent shape differences (circular for red, rectangular for green, triangular for blue) without requiring external alignment keys or complex alignment mechanisms. This self-service approach eliminates the need for separate alignment processes and significantly improves transfer efficiency while reducing manufacturing costs
Solution Approach 2:
The patent extracts the alignment function from separate alignment keys and integrates it directly into the microLEDs themselves through shape encoding. By removing the need for external alignment structures, the process becomes simpler and more efficient
2Productivity
If laser lift-off method is used to transfer microLEDs, then transfer of semiconductor light-emitting devices can be achieved, but manufacturing efficiency is low and cost is high
Solution Approach 1:
The microLEDs perform self-alignment through their inherent shape differences (circular for red, rectangular for green, triangular for blue) without requiring external alignment keys or complex alignment mechanisms. This self-service approach eliminates the need for separate alignment processes and significantly improves transfer efficiency while reducing manufacturing costs
Solution Approach 2:
The patent extracts the alignment function from separate alignment keys and integrates it directly into the microLEDs themselves through shape encoding. By removing the need for external alignment structures, the process becomes simpler and more efficient
3Area of stationary object
If self-assembly method is used to transfer microLEDs, then large-screen display devices can be realized, but alignment precision must be improved
Solution Approach 1:
Each microLED type has a distinct local geometric quality (circular, rectangular, or triangular shape) that encodes its color identity and orientation information. This local quality differentiation enables precise self-alignment and correct orientation during self-assembly, achieving high alignment precision across large display areas
Solution Approach 2:
The patent introduces asymmetry in the shapes of different colored microLEDs (circular for red, rectangular for green, triangular for blue) to enable directional recognition and correct orientation during self-assembly. This asymmetric design ensures that each microLED automatically orients itself correctly without external alignment assistance
Data Source
AI summary
A display device according to the present invention comprises: a wiring board including a plurality of pixel areas; and semiconductor light-emitting devices disposed in the pixel areas, wherein the pixel areas include semiconductor light-emitting devices having different shapes and emitting different colors, and wherein the wiring board has two or more pixel areas having different arrangements of the semiconductor light-emitting devices. The present invention may be used as an align key when manufacturing a display device by varying the arrangement of semiconductor light-emitting devices in some pixel areas.