Micro-LED Pixel Layout for Precise Self-Assembly Alignment
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Solution Overview
Problem
Current display technologies using inorganic light emitting diodes face challenges in achieving high yield and efficiency in manufacturing, particularly in arranging and integrating light emitting diodes of different sizes on a substrate for optimal color representation and energy efficiency.
Innovation Solution
A display module design featuring a plurality of thin film transistors (TFTs) on a substrate with differently sized light emitting diodes (blue, green, and red) of trapezoidal shape, arranged in specific patterns and sizes, and a manufacturing method using fluidic self-assembly with molds of corresponding shapes to precisely position and adhere these diodes on a TFT substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light emitting diodes of different sizes are arranged on a substrate for optimal color representation, then color quality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the manufacturing process into separate stages: first forming a common electrode layer across the entire substrate, then separately forming hole injection layers and hole transport layers in different patterns and thicknesses for different pixel regions. This segmentation allows different sized LEDs to be manufactured on the same substrate without requiring completely separate production lines for each size.
Solution Approach 2:
The patent creates a universal manufacturing platform where a single substrate can accommodate multiple LED sizes (small, medium, large) by using a common electrode layer structure that serves all pixel types. The hole injection and transport layers are designed with variable patterns and thicknesses that can be adapted to different LED sizes while maintaining the same basic fabrication process.
2Productivity
If differently sized light emitting diodes are integrated on a single substrate, then manufacturing efficiency is improved, but alignment precision requirements increase
Solution Approach 1:
The patent performs preliminary actions by first forming the common electrode layer across the entire substrate before forming the hole injection and transport layers. This preliminary structure provides a stable foundation that simplifies subsequent alignment steps, as the electrode layer already defines the pixel boundaries and patterns that guide where different sized LEDs will be placed.
Solution Approach 2:
The patent applies local quality variations to the hole injection and transport layers, where the thickness and pattern of these layers are specifically tailored for different pixel regions containing different sized LEDs. This allows each region to be optimized for its specific LED size while maintaining consistent manufacturing processes across the entire substrate.
3Productivity
If multiple thin film transistors are arranged on a flexible substrate, then device integration is improved, but substrate stability challenges increase
Solution Approach 1:
The patent segments the substrate into distinct pixel regions, each with its own TFT and LED configuration. This segmentation allows the flexible substrate to be designed with local reinforcement or support structures in critical areas while maintaining overall flexibility. The common electrode layer also acts as a stabilizing element that distributes mechanical stresses across the entire substrate.
Data Source
AI summary
A display apparatus is provided. The display apparatus includes a plurality of thin film transistors (TFTs) provided on a substrate; and a plurality of pixels electrically connected to the plurality of TFTs. Each pixel includes a first light emitting diode, a second light emitting diode, and a third light emitting diode having different sizes from one another.