Vertically Stacked LED Structure for Compact Micro LED Repair
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Solution Overview
Problem
The existing micro LED system with a horizontal structure of red, green, and blue LEDs is difficult to miniaturize and repair due to its layout, making it challenging to reduce the light-emitting area and replace damaged components efficiently as electronic products become smaller.
Innovation Solution
A vertically stacked LED structure where multiple light-emitting devices are stacked on a substrate, with electrodes extending to pads for reduced area and easy replacement, allowing the entire substrate to be removed and replaced when damaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If micro LEDs are arranged horizontally as in prior art, then the light-emitting area is larger and easier to manufacture, but the overall area cannot be reduced and repair is difficult
Solution Approach 1:
The patent transitions from a horizontal arrangement of micro LEDs to a vertical stacking configuration. Multiple micro LEDs are stacked in the vertical dimension, allowing the light-emitting structure to occupy less horizontal area while maintaining or increasing total light output. This dimensional change enables both area reduction and improved repairability, as the vertical stack can be replaced as a modular unit.
Solution Approach 2:
The patent divides the light-emitting structure into separable modules, where individual micro LEDs or groups of stacked LEDs can be independently replaced. This segmentation allows damaged components to be substituted without replacing the entire display, significantly improving repairability while maintaining a compact footprint.
2Ease of manufacture
If micro LEDs are arranged horizontally, then manufacturing is easier, but the overall structure area cannot be reduced for miniaturization
Solution Approach 1:
By stacking micro LEDs vertically rather than arranging them horizontally, the patent reduces the horizontal footprint of the light-emitting structure. This vertical integration maintains manufacturing feasibility while enabling miniaturization of the overall device, as the stacked configuration occupies less planar space.
Solution Approach 2:
The patent implements a nested structure where multiple micro LEDs are stacked one on top of another, similar to nested dolls. This nesting approach allows multiple light-emitting elements to be integrated within a compact vertical space, reducing the overall structure area while maintaining the ability to manufacture each component separately.
3Quantity of substance
If horizontal arrangement is used, then more LEDs can be placed, but replacement and repair become difficult due to the structure
Solution Approach 1:
The vertical stacking configuration allows the LED structure to be divided into replaceable modules. When LEDs are stacked vertically, damaged units can be accessed and replaced by removing and replacing the entire stack or individual components, which is simpler than navigating a horizontal array where LEDs are interconnected across a larger area.
Solution Approach 2:
By organizing LEDs in the vertical dimension rather than spreading them horizontally, the patent creates a compact, accessible structure. This vertical arrangement allows for easier removal and replacement of the LED stack as a unit, improving repairability while maintaining or increasing the number of LEDs through the stacking configuration.
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 configuration reduces the overall light-emitting area and facilitates rapid repair by enabling the entire vertically stacked structure to be replaced, addressing the challenges of miniaturization and repair in traditional micro LED systems.
Implementation Method 1
a first reflection layer... disposed on the first light-emitting device
Implementation Method 2
a second reflection layer... disposed on the second light-emitting device
Data Source
AI summary
The present invention provides a vertically stacked light-emitting diode (LED) structure, which comprises a substrate, a first light-emitting device, a first reflection layer, a second light-emitting device, a second reflection layer, and a third light-emitting device. The layers are stacked sequentially. The first light-emitting device, the second light-emitting device, and the third light-emitting device are connected electrically to the pads located on the edges of the substrate. In addition, the first reflection layer and the second reflection layer are used to reflect and filter the light from the first light-emitting device, the second light-emitting device, and the third light-emitting device. By using this structure, the area of the light-emitting diode structure can be further shrunk.