Monolithic Micro-LED Growth Reduces Transfer Defects
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Solution Overview
Problem
Micro-LED displays face challenges in reducing power consumption and production costs, particularly in mobile devices where displays account for a significant portion of power consumption, and current transfer processes are inefficient and prone to defects.
Innovation Solution
The solution involves growing monolithically two types of micro-LEDs with different indium compositions on the same wafer, allowing for simultaneous production of multiple color LEDs with varying indium content, which reduces the number of transfer processes and defects, and uses a stamp to transfer these LEDs onto a backplane, thereby decreasing the transfer time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple transfer processes are used to produce different color micro-LEDs, then color variety is achieved, but production time and defect rate increase
Solution Approach 1:
The patent combines multiple micro-LED structures with different indium compositions (and thus different emission colors) onto a single wafer using monolithic growth. This allows multiple color LEDs to be produced simultaneously in one growth process rather than requiring separate transfer processes for each color, thereby reducing production time while maintaining color variety.
Solution Approach 2:
The patent creates a universal wafer structure that can produce multiple types of micro-LEDs (different colors) through a single growth process. The same wafer and growth process serve multiple functions by accommodating different indium compositions that emit different colors, eliminating the need for separate specialized processes for each color type.
2Adaptability or versatility
If multiple transfer processes are used to produce different color micro-LEDs, then color variety is achieved, but defect rate increases
Solution Approach 1:
The patent merges multiple micro-LED structures with different indium compositions onto a single wafer through monolithic growth. This consolidation reduces the number of separate transfer processes required, thereby minimizing the accumulation of defects that would occur with multiple sequential transfers while still achieving diverse color output.
3Manufacturing precision
If different MOVPE process parameters are used for different color LEDs, then color precision is achieved, but process complexity increases
Solution Approach 1:
The patent applies local quality by allowing different indium compositions (and thus different emission colors) to grow simultaneously on the same wafer under the same MOVPE process parameters. Each local region on the wafer produces LEDs with specific color characteristics determined by its indium composition, while the overall process remains simple and unified.
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 results in lower power consumption, reduced defects, and lower production costs for micro-LED displays by minimizing the number of transfer steps and utilizing the same MOVPE process parameters for multiple color LEDs, enhancing power efficacy and cost-effectiveness.
Implementation Method 1
Displays having microscopic light-emitting diodes (LEDs) are known as micro-LED, mLED, and μLED
Implementation Method 2
utilizing the same MOVPE process parameters for multiple color LEDs
Data Source
AI summary
A micro-light emitting diode (LED) display panel and a method of forming the display panel, the micro-LED display panel having a monolithically grown micro-structure including a first color micro-LED that is a first color nanowire LED, and a second color micro-LED that is a second color nanowire LED.