Vertically Stacked LED Display Panel for Smaller Multi-Color Pixels
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Solution Overview
Problem
Existing display panel manufacturing methods require multiple light emitting diodes (LEDs) to produce a single pixel, leading to increased complexity and reduced efficiency in terms of pixel area and manufacturing process simplicity.
Innovation Solution
A display panel design that incorporates vertically stacked light emitting diodes (LEDs) with a color conversion layer and a transparent optical layer, allowing for the emission of multiple colors from a single LED type, thereby reducing the number of LEDs required per pixel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple light emitting diodes are used to produce a single pixel, then color emission capability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent transitions from a planar arrangement of multiple LEDs to a vertically stacked three-dimensional structure. Multiple light emitting diodes are arranged in vertical layers rather than horizontal planes, allowing multiple colors to be emitted from a single pixel location without increasing lateral complexity. This vertical stacking enables color diversity while maintaining compact pixel structure.
Solution Approach 2:
The vertically stacked LED structure serves multiple functions within a single integrated unit. Different LED layers emit different colors (e.g., blue, green, red), and the structure incorporates both light emitting parts and color conversion layers that work together to produce the desired color output. This multi-functional integration reduces the need for separate components for each color channel.
2Adaptability or versatility
If multiple light emitting diodes are used to produce a single pixel, then color emission capability is improved, but manufacturing process complexity increases
Solution Approach 1:
The manufacturing process is divided into distinct stages: first, multiple light emitting diodes are formed on a wafer in vertical stacks; second, the complete vertically stacked structures are transferred as unified units to the substrate; third, color conversion layers are formed on the transferred structures. This segmentation allows each manufacturing step to be optimized independently, simplifying the overall process despite the complex final structure.
Solution Approach 2:
The light emitting diodes and their vertical stacking are prepared in advance on a wafer before transfer to the final substrate. This preliminary formation allows for precise control of LED positioning and stacking in a controlled environment, and the pre-assembled vertical structures are then transferred as complete units, reducing manufacturing complexity at the final assembly stage.
3Adaptability or versatility
If multiple light emitting diodes are used to produce a single pixel, then color emission capability is improved, but pixel area increases
Solution Approach 1:
The patent resolves the area conflict by moving from a two-dimensional lateral arrangement to a three-dimensional vertical arrangement. Multiple LEDs that would traditionally occupy separate lateral spaces are instead stacked vertically within the same lateral footprint. This allows a single pixel to emit multiple colors through vertical layering without increasing the horizontal pixel area, thereby improving color capability while maintaining compact pixel dimensions.
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 pixel structure and manufacturing process, reduces the area occupied by each pixel to about ⅔ of the original size, and improves the efficiency of color emission by using fewer LEDs per pixel.
Implementation Method 1
a color conversion layer on a light emitting surface of the first light emitting part, the color conversion layer including a quantum dot configured to emit light of the first color by exciting lights respectively emitted from the first light emitting part and the second light emitting part
Data Source
AI summary
A display panel includes: a substrate; a plurality of substrate electrodes on the substrate; a plurality of first light emitting diodes electrically connected to the plurality of substrate electrodes, and configured to emit light of a first color; and a plurality of second light emitting diodes electrically connected to the plurality of substrate electrodes, each of the plurality of second light emitting diodes being configured to emit light of a second color and emit light of a third color, wherein the second color and the third color are different from the first color.