RGB Light Emitting Module With Horizontal LED Stacking
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Solution Overview
Problem
The challenge in manufacturing LED displays is the increased time consumption in the mounting process due to the need for precise arrangement of multiple light emitting devices to achieve various colors, and the restriction of stacking sequence by light wavelengths, as well as interference of light emitting regions by electrodes.
Innovation Solution
A novel structure for LED displays is introduced, where light emitting devices are stacked horizontally on a display substrate, allowing independent operation of LED units with electrodes positioned to avoid light interference, and using bonding layers that do not obstruct light emission, enabling flexible stacking sequences and reduced device count per pixel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple light emitting devices are arranged to emit various colors, then color variety is improved, but time consumption in mounting process increases
Solution Approach 1:
The patent combines multiple LED units (first LED unit, second LED unit, third LED unit) into a single integrated light emitting device structure. These units are coupled together through bonding layers and share a common electrode, allowing them to function as one mounting unit while still providing multiple colors (red, green, blue) through their respective light emitting stacks.
2Productivity
If light emitting devices are stacked to reduce device count, then mounting efficiency is improved, but stacking sequence is restricted by light wavelengths
Solution Approach 1:
The patent transitions from traditional vertical stacking (restricted by wavelength) to horizontal coupling of LED units. The first, second, and third LED units are arranged side-by-side and coupled through bonding layers in a horizontal direction, with light emitting in a direction perpendicular to the coupling direction. This dimensional change eliminates wavelength-based stacking restrictions.
Solution Approach 2:
The light emitting device is segmented into multiple independent LED units (first LED unit, second LED unit, third LED unit), each with its own light emitting stack. These segmented units can be independently configured and coupled together, providing flexibility in arrangement without wavelength constraints.
3Reliability
If electrodes are added to control LED units, then electrical connection is improved, but light emitting regions are interfered with
Solution Approach 1:
The patent introduces bonding layers as intermediary elements that couple the LED units together. These bonding layers facilitate both electrical connection (through electrode connections) and mechanical bonding, while being positioned and designed to minimize interference with the light emitting regions of the LED units.
Solution Approach 2:
The electrodes are positioned locally at specific regions of the LED units rather than covering the entire structure. The common electrode and individual electrodes are strategically placed to provide necessary electrical connections while leaving the light emitting regions substantially unobstructed.
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 reduces the number of light emitting devices required per pixel to 1/3, allows for flexible stacking without wavelength restrictions, and enhances color mixing and contrast ratios, facilitating efficient manufacturing and improved display performance.
Implementation Method 1
a first bonding layer coupling the first LED unit to the second LED unit, and a second bonding layer coupling the second LED unit to the third LED unit
Data Source
AI summary
A light emitting module including a circuit substrate and light emitters arranged side by side thereon. A first light emitter can include a first layer stack, a second light emitter includes a second layer stack, and a third light emitter includes a third layer stack, and each stack can include a first conductivity type semiconductor layer and a second conductivity type semiconductor layer. A light transparent layer can be configured to transmit light emitter by the first, second, and third light emitters, and a reflector including a white material can be located adjacent to the first, second, and third light emitters. A stack direction in each of the first, the second and the third light emitters is not perpendicular to an upper surface of the light transparent layer.