Micro-LED Stacked Pixel Structure for Easier Full-Color Assembly
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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 assembling the display panels.
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 on top of each other, emitting different colored light and having overlapping light emitting areas, allowing for high color purity and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If micro-LEDs are arranged on a two-dimensional plane with each subpixel requiring separate mounting, then color display capability is achieved, but manufacturing complexity and assembly difficulty increase significantly
Solution Approach 1:
The patent combines multiple micro-LEDs of different colors (red, green, blue) into a single integrated pixel structure. Instead of mounting separate micro-LEDs for each subpixel, the invention integrates them into one unified component that can be mounted as a single unit, thereby reducing assembly complexity while maintaining full color display capability
Solution Approach 2:
The patent transitions from a two-dimensional arrangement of separate micro-LEDs to a three-dimensional stacked structure where multiple light-emitting layers are vertically integrated. This dimensional change allows multiple colors to be combined in a compact vertical configuration rather than requiring extensive horizontal spacing for individual mounting
2Manufacturing precision
If micro-LEDs are made very small to achieve high resolution, then display pixel density improves, but mounting and replacement difficulty increases
Solution Approach 1:
By combining multiple tiny micro-LEDs into a single integrated pixel, the invention effectively increases the operational size for mounting purposes while maintaining the small physical footprint needed for high pixel density. The integrated pixel can be handled and mounted as one unit rather than requiring manipulation of individual sub-micro-LED components
3Adaptability or versatility
If separate mounting processes are used for each micro-LED, then individual color control is achieved, but production time and manufacturing cost increase
Solution Approach 1:
The integrated pixel structure allows all color subpixels to be manufactured and tested as a single unit, enabling parallel processing and quality assurance. This merging approach maintains individual color control capability while dramatically reducing the number of separate mounting and testing operations required
Solution Approach 2:
The invention performs preliminary integration of multiple micro-LEDs into a single pixel structure during the manufacturing process, before the mounting stage. This preliminary action ensures that color coordination and electrical connections are established in advance, eliminating the need for complex on-site assembly and testing operations
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 color accuracy, while simplifying the manufacturing process by reducing the number of assembly steps and increasing the efficiency of micro-LED placement.
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.