Stacked Micro LED Light Emitter Structure for Small Bright Pixels
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Solution Overview
Problem
Micro LED displays face challenges in handling small-sized LEDs, difficulty in mounting and replacing defective LEDs, increased pixel area due to subpixel arrangement, and reduced brightness from reduced luminous area.
Innovation Solution
A light emitting stacked structure with epitaxial sub-units emitting different wavelengths stacked on a substrate, each sub-unit connected by contact parts for common voltage and signal application, allowing independent driving and light transmission between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If micro LEDs are arranged on a two-dimensional plane, then the display can be manufactured, but the pixel area increases and the luminous area per subpixel decreases
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement of subpixels to a three-dimensional stacked structure where red, green, and blue light-emitting layers are vertically stacked. This vertical stacking allows subpixels to share the same lateral footprint while maintaining distinct color emission, thereby reducing pixel area without compromising luminous area or brightness.
2Area of stationary object
If the area of each subpixel is reduced to arrange subpixels within a limited area, then the pixel area decreases, but the brightness deteriorates
Solution Approach 1:
By stacking light-emitting layers vertically in the third dimension, the patent enables multiple subpixels to occupy the same lateral space. Each layer maintains its full luminous area while the overall pixel footprint is reduced, thus improving brightness density without sacrificing total light output.
Solution Approach 2:
The patent implements a nested structure where red, green, and blue light-emitting layers are stacked one above another, with each layer containing or supporting the others. This nesting allows the layers to share common infrastructure such as contact parts and substrates, reducing overall pixel area while maintaining the luminous area of each color channel.
3Ease of manufacture
If individually grown red, green, and blue LED structures are formed on a final substrate, then the display can be manufactured, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the manufacturing process by forming red, green, and blue light-emitting layers simultaneously or sequentially on a single substrate using unified contact parts and shared fabrication steps. This consolidation reduces the number of separate manufacturing processes required compared to individually grown LED structures, thereby simplifying manufacturing while reducing structural complexity.
4Productivity
If a large number of micro LEDs are disposed on one substrate, then the display resolution increases, but the handling and mounting difficulty increases
Solution Approach 1:
The patent nests multiple light-emitting layers within a unified stacked structure that shares common contact parts and substrate infrastructure. This nested architecture allows high-density arrangement of subpixels while reducing the number of independent components that need to be handled and mounted separately, thereby improving ease of operation without sacrificing display resolution.
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
Increases light emitting area per subpixel without increasing pixel size, improves color purity and reproduction, simplifies manufacturing by reducing complexity and enhancing connectivity.
Implementation Method 1
each epitaxial sub-unit configured to emit light having different wavelength bands from each other in a first direction
Data Source
AI summary
A light module including a circuit substrate and a light emitter, the light emitter including a light source configured to generate light and including a first epitaxial layer, a second epitaxial layer, and an active layer, an insulation layer covering the light source, a first electrode electrically connected to the first epitaxial layer, a light guide configured to guide light generated from the light source, a transparent material covering the light source, and an angle controller disposed on the transparent material, in which the light guide has a guide hole filled with the transparent material, and a refractive index of the light guide is different from that of the light source.