Pixel Module IC Integration for High-Resolution Micro-LED Displays
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Solution Overview
Problem
Existing inorganic LED displays face challenges in achieving high resolution, improved manufacturability, and reduced costs due to large pixel sizes and low pixel pitches, limiting their performance and efficiency compared to OLED or liquid crystal displays.
Innovation Solution
The development of integrated-circuit modules with native and non-native components, including semiconductor substrates, integrated circuits, and light emitters, where electrodes connect controllers to light emitters through vias, enabling high-density, high-resolution displays through micro-transfer printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inorganic LED displays use relatively large iLEDs (one mm or more) mounted in display frames, then manufacturing is simplified and costs are reduced, but pixel pitch increases to approximately 25 ppi, resulting in low resolution
Solution Approach 1:
The display is divided into modular pixel modules, each containing a small integrated circuit and multiple light emitters (micro-LEDs or nanoscale LEDs). This segmentation allows precise positioning of individual pixels to achieve high resolution (e.g., 4K or higher) while maintaining ease of manufacture through modular assembly processes.
Solution Approach 2:
The patent transitions from two-dimensional array arrangements to three-dimensional stacked configurations, with light emitters positioned at different heights above the substrate. This vertical stacking enables higher pixel density without increasing lateral complexity, resolving the contradiction between resolution and manufacturability.
2Manufacturing precision
If inorganic LED displays use small integrated circuits and micro-LEDs distributed over large display substrates, then resolution is improved, but device complexity increases due to distributed control requirements
Solution Approach 1:
The patent merges the controller and light emitters into integrated pixel modules, where each module is a self-contained unit with integrated control circuitry. This consolidation reduces overall system complexity compared to fully distributed control, while still enabling high resolution through the modular architecture.
Solution Approach 2:
Each pixel module serves multiple functions: it acts as both a light-emitting element and a controlled unit with integrated circuitry. This multi-functionality reduces the need for separate control systems for each pixel, simplifying the overall control architecture while maintaining high resolution.
3Device complexity
If inorganic LED displays use external controllers and large iLEDs, then device complexity is reduced, but pixel size increases, limiting display performance and efficiency
Solution Approach 1:
The patent implements a nested structure where small integrated circuits are embedded within or adjacent to light emitters, forming compact pixel modules. These modules are then arranged in arrays on the display substrate. This nesting approach maintains relatively simple overall control structure while achieving small pixel sizes through efficient space utilization.
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 allows for the construction of high-performance, high-resolution displays with improved manufacturability and reduced costs by integrating crystalline semiconductor light emitters and controllers, enhancing color saturation, efficiency, and operational performance.
Implementation Method 1
an organic light-emitting diode (in the case of an OLED display). Inorganic light-emitting diodes are also used in flat-panel displays.
Implementation Method 2
The pixels in each selected row receive data on the column wires and store the data locally in the pixel. Once the data is received and stored, it is displayed at each pixel by the control circuitry in the pixel by providing power to the pixel control circuitry, for example transistors driving electrodes controlling a liquid crystal (in the case of a liquid crystal display) or an organic light-emitting diode (in the case of an OLED display).
Data Source
AI summary
An example of a pixel module comprises a module substrate having light emitters disposed on a light-emitter surface and a controller disposed on a controller surface opposed to the light-emitter surface. At least one module electrode is electrically connected to the controller and at least one module electrode is electrically connected to each light emitter. An example of a pixel-module wafer comprises a module source wafer comprising sacrificial portions and module anchors, each sacrificial portion laterally separated from an adjacent sacrificial portion by a module anchor and a pixel module disposed entirely over each sacrificial portion. At least one module tether physically connects each of the pixel modules to at least one of the module anchors. An example of a pixel-module display comprises a display substrate, pixel modules disposed on the display substrate and display electrodes disposed on the display substrate, each display electrode electrically connected to a module electrode.