Micro-LED Stacked Pixel Tiles for High-Resolution Color Displays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in efficiently manufacturing and mounting micro-LEDs on a display panel due to their small size, which complicates the process of creating high-resolution displays with precise color reproduction.
Innovation Solution
The proposed solution involves a light emitting stacked structure with epitaxial sub-units that can be manufactured using a simplified method, allowing for simultaneous production of pixels and enabling high color purity and reproducibility in displays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro-LEDs are arranged on a two-dimensional plane to create high-resolution displays, then color purity and reproducibility are improved, but the complexity of mounting and manufacturing increases significantly
Solution Approach 1:
The patent transitions from traditional two-dimensional planar arrangement of micro-LEDs to a three-dimensional stacked structure where multiple micro-LEDs are vertically stacked. This dimensional change allows multiple light-emitting elements to occupy a smaller footprint area while maintaining color purity through selective wavelength emission from each stack, thereby reducing mounting complexity without sacrificing display quality.
Solution Approach 2:
The patent combines multiple micro-LEDs of different colors (red, green, blue) into a single vertical stack structure. Instead of mounting separate micro-LEDs side-by-side on the substrate, they are merged into one integrated stacked unit that can be mounted as a single component, significantly simplifying the mounting process while maintaining the ability to produce pure colors through selective activation of individual LEDs within the stack.
2Manufacturing precision
If the number of micro-LEDs is increased to achieve high-resolution displays, then display quality is improved, but the difficulty of mounting and replacing defective LEDs increases
Solution Approach 1:
By stacking micro-LEDs vertically in the third dimension, the patent achieves high display resolution without proportionally increasing the number of mounting operations. Multiple high-resolution pixels are created within a compact vertical stack, reducing the total number of separate mounting operations required compared to traditional planar arrangements.
Solution Approach 2:
The patent segments the display into modular stacked units that can be manufactured and tested independently before final assembly. This segmentation allows for easier replacement of defective stacks as complete units rather than requiring individual LED replacement, significantly improving ease of operation and maintenance.
3Manufacturing precision
If micro-LEDs are made smaller to increase pixel density, then display resolution is improved, but the difficulty of mounting and handling increases
Solution Approach 1:
The patent merges multiple small micro-LEDs into a single stacked structure, effectively creating a larger functional unit from smaller components. This merging approach allows the benefits of small, high-density LEDs to be realized while the entire stack can be handled and mounted as a single unit, maintaining ease of manufacture despite the small individual LED size.
Solution Approach 2:
By arranging small micro-LEDs vertically in stacks rather than spreading them out in two dimensions, the patent achieves high pixel density without proportionally increasing the difficulty of mounting. The vertical stacking allows small LEDs to be consolidated into fewer, manageable units that can be handled more easily than equivalent numbers of individual planar LEDs.
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 simplifies the manufacturing process, reduces the complexity of mounting micro-LEDs, and achieves high color purity and reproducibility, making it suitable for high-resolution display applications.
Implementation Method 1
Light emitting diodes have been used in various technical fields, such as displays
Implementation Method 2
Each of the light emitting stacked structures may include a plurality of epitaxial sub-units sequentially disposed one over another
Data Source
AI summary
A display device includes a plurality of pixel tiles spaced apart from each other, each of the pixel tiles including a substrate and a plurality of light emitting stacked structures disposed on the substrate, in which a distance between two adjacent light emitting stacked structures in the same pixel tile is substantially equal to a shortest distance between two adjacent light emitting stacked structures of different pixel tiles.