Micro-LED Stacked Epitaxial Structure for High-Resolution Displays
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Solution Overview
Problem
The challenge in micro-LED display technology is the difficulty in mounting and replacing micro-LEDs due to their small size, which requires a complex and inefficient process for manufacturing and assembly.
Innovation Solution
The proposed solution involves a light emitting stacked structure with a simplified manufacturing method, where pixels are manufactured simultaneously, eliminating the need for individual mounting of LEDs. This structure includes a substrate with epitaxial sub-units stacked sequentially, emitting different colored light and having overlapping light emitting areas, allowing for high color purity and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro-LEDs are arranged on a two-dimensional plane with small size, then high resolution display is achieved, but mounting and replacement difficulty increases
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement of micro-LEDs to a three-dimensional stacked structure where multiple micro-LEDs are vertically arranged on a single substrate. This vertical stacking enables high-resolution displays by increasing the number of subpixels per pixel region without requiring proportional increases in mounting complexity, as all micro-LEDs in a stack are mounted together as a unit.
Solution Approach 2:
The patent combines multiple micro-LEDs (red, green, and blue subpixels) into a single stacked structure that functions as one integrated unit. This merging approach allows simultaneous mounting and replacement of multiple micro-LEDs, significantly improving ease of operation while maintaining high display resolution through the combined light-emitting capabilities of all subpixels in the stack.
2Manufacturing precision
If different types of micro-LEDs are grown on different substrates, then color purity is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple micro-LEDs grown on different substrates into a single integrated stacked structure. By combining red, green, and blue micro-LEDs (each potentially grown on optimized substrates for their specific wavelengths) into one stack, the patent maintains high color purity while reducing device complexity through unified mounting and integration processes.
Solution Approach 2:
The patent resolves substrate management complexity by transitioning from horizontal arrangement of multiple substrates to vertical stacking on a single substrate. This dimensional change allows different types of micro-LEDs to be integrated in the vertical dimension while simplifying substrate management to a single base substrate, thereby reducing overall device complexity.
3Ease of manufacture
If micro-LEDs are arranged in stacked structure, then manufacturing process is simplified, but light extraction efficiency may be affected
Solution Approach 1:
The patent arranges micro-LEDs in a vertical stacked configuration, simplifying manufacturing by enabling simultaneous processing and mounting of multiple micro-LEDs in one operation. The vertical arrangement in the third dimension allows light to be extracted through the top surface of the stack, maintaining efficient light extraction while achieving manufacturing simplicity through the stacked architecture.
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 the production of high-resolution display devices with improved light extraction efficiency and simplified manufacturing, reducing the complexity and cost associated with traditional micro-LED assembly methods.
Implementation Method 1
Each of the light emitting stacked structures may include a first epitaxial sub-unit disposed on the support substrate, a second epitaxial sub-unit disposed on the first epitaxial sub-unit, and a third epitaxial sub-unit disposed on the second epitaxial sub-unit
Data Source
AI summary
A display apparatus including a plurality of pixel regions disposed on a support substrate, each of the pixel regions including a plurality of subpixel stacks including a first epitaxial stack, a second epitaxial stack, and a third epitaxial stack, in which light generated from the first epitaxial stack is to be emitted to the outside of the display apparatus through the second and third epitaxial stacks, light generated from the second epitaxial stack is to be emitted to the outside of the display apparatus through the third epitaxial stack, during operation, one of the subpixel stacks within each pixel region is configured to be selected and driven, and at least one subpixel stack further includes an electrode disposed between the first epitaxial stack and the support substrate to be in ohmic contact with the first epitaxial stack.