Stacked LED Pixel Structure for Bright Full-Color Displays
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Solution Overview
Problem
Micro light-emitting diodes (LEDs) for display devices face challenges due to their small form factor, making handling and mounting difficult, leading to issues with brightness and manufacturing complexity, as well as requiring a large number of LEDs, which increases the likelihood of defects and reduces manufacturing efficiency.
Innovation Solution
A stacked light-emitting diode structure with inclined sides to facilitate an optically non-transmissive film, maximizing light reflection and preventing light leakage, allowing for the simultaneous manufacturing of multiple pixels and increasing the luminous area without increasing pixel size, and incorporating hydrophilic and shock-absorbing layers to enhance adhesion and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If micro LEDs are arranged on a two-dimensional plane to correspond to each sub-pixel, then the display can achieve full-color capability, but the area occupied by one pixel becomes relatively large
Solution Approach 1:
The patent transitions from a two-dimensional arrangement of separate R, G, B sub-pixels to a three-dimensional stacked structure where multiple LED layers are vertically arranged. This dimensional change allows multiple color-emitting layers to occupy the same horizontal footprint, significantly reducing the pixel area while maintaining full-color capability through vertical integration of red, green, and blue LED layers.
2Area of stationary object
If the area of each LED chip is reduced to arrange sub-pixels within a limited area, then the pixel size can be reduced, but the brightness of sub-pixels deteriorates due to reduction of light emitting area
Solution Approach 1:
By stacking multiple LED layers vertically, the patent increases the total light-emitting area in the vertical dimension while keeping the horizontal pixel size small. Multiple LED chips in the stack collectively emit light, compensating for the reduced individual chip area and maintaining sufficient brightness despite the compact pixel footprint.
Solution Approach 2:
The patent combines multiple LED layers (red, green, blue) into a single integrated pixel structure. The light output from all layers is merged and emitted through the pixel, creating a combined brightness effect that compensates for the small individual chip areas while maintaining the reduced pixel size.
3Manufacturing precision
If a large number of micro LEDs are required for a typical display panel, then full-color high-resolution display can be achieved, but the likelihood of defects increases and manufacturing efficiency reduces
Solution Approach 1:
The patent merges multiple LED layers into integrated pixel units, reducing the total number of separate mounting operations required. By fabricating and integrating multiple color layers together in a stacked configuration, the system reduces the number of discrete components that need to be individually placed and connected, thereby lowering the cumulative defect probability and improving manufacturing efficiency.
4Adaptability or versatility
If individually-grown red, green, and blue LED structures are formed on a final substrate, then full-color display capability can be achieved, but the manufacturing method becomes complex
Solution Approach 1:
The patent employs vertical stacking of LED layers in the third dimension, allowing multiple color structures to be integrated in a compact vertical arrangement rather than requiring extensive lateral spacing and complex routing. This three-dimensional integration simplifies the manufacturing process by reducing the number of separate fabrication stages and alignment operations needed compared to traditional planar arrangements.
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
The solution enables the efficient manufacturing of high-reliability display devices with increased brightness and reduced defect rates, allowing for passive or active matrix driving and simplifying the mounting process, while maintaining a compact form factor.
Implementation Method 1
the light reflection effect of the optically non-transmissive film may be maximized or substantially increased
Data Source
AI summary
A display apparatus including a substrate, and pixel regions and at least one separation region between the pixel regions, each pixel region including a first LED stack, a second LED stack adjacent to the first LED stack, a third LED stack adjacent to the second LED stack and each having a side surface forming a first angle, a second angle, and a third angle with the substrate, respectively, electrode pads electrically connected to the first, second, and third LED stacks, and an insulation layer disposed on at least one of the first, second, and third LED stacks, in which the first LED stack is configured to emit light having a longer peak wavelength than that emitted from the second and third LED stacks, and the first angle is different from the second and third angles.