Stacked Micro-LED Pixel Structure for High-Resolution Color Displays
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Solution Overview
Problem
Micro-LEDs with small sizes pose challenges in mounting on display panels due to their small surface area, necessitating high-resolution and full-color displays with improved color purity and reproducibility, while existing methods are complex and inefficient.
Innovation Solution
A light emitting stacked structure with epitaxial sub-units emitting different colors, where each sub-unit has an overlapping area and energy band, allowing for independent driving and efficient light transmission, thereby increasing the light emitting area without enlarging the pixel size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro-LEDs are arranged on a two-dimensional plane to achieve high-resolution display, then the number of micro-LEDs required increases to hundreds of thousands or millions, but the mounting difficulty increases significantly due to their very small size with surface area of about 10,000 square μm or less
Solution Approach 1:
The patent transitions from a two-dimensional arrangement of micro-LEDs to a three-dimensional stacked structure where multiple micro-LEDs are vertically integrated. This vertical stacking allows multiple light-emitting elements to occupy a smaller planar footprint, reducing the total number of individual mounting operations required while maintaining high display resolution.
Solution Approach 2:
The patent combines multiple micro-LEDs into a single stacked structure that functions as one integrated light-emitting unit. By merging multiple LEDs vertically, the system reduces the number of separate mounting operations needed and simplifies the manufacturing process while achieving high-resolution display capabilities.
2Manufacturing precision
If the light emitting area of each subpixel is increased to improve color purity and reproducibility, then the pixel area must be enlarged, but this reduces the number of pixels that can be displayed on the same panel
Solution Approach 1:
The patent utilizes the vertical dimension by stacking multiple micro-LEDs one on top of another. This allows the light-emitting area to be increased through vertical integration rather than horizontal expansion, enabling larger effective emitting areas within the same pixel footprint and maintaining high pixel density on the display panel.
Solution Approach 2:
The patent implements a nested structure where multiple micro-LEDs are stacked vertically within a single pixel location. This nesting approach allows multiple light-emitting elements to be contained within a compact volume, increasing the effective light-emitting area without proportionally increasing the pixel area.
3Manufacturing precision
If individual mounting of light emitting diodes is performed to achieve precise positioning, then the manufacturing process becomes complex and time-consuming, but skipping this step may reduce positioning accuracy
Solution Approach 1:
The patent combines multiple micro-LEDs into pre-assembled stacked structures before integration onto the display panel. This merging approach allows the complex positioning requirements to be satisfied at the stack level rather than at the individual LED level, significantly simplifying the manufacturing process while maintaining positioning accuracy.
Solution Approach 2:
The patent performs preliminary assembly of multiple micro-LEDs into stacked structures before final integration onto the display panel. This preliminary action allows precise positioning to be achieved during the stack formation process, reducing the complexity of the final mounting operation while ensuring accurate positioning.
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 high-resolution and full-color displays with simplified manufacturing, achieving enhanced color purity and reproducibility by utilizing a stacked structure that efficiently combines red, green, and blue light emissions from micro-LEDs.
Implementation Method 1
a plurality of epitaxial sub-units disposed one over another, each of the epitaxial sub-units configured to emit different colored light
Implementation Method 2
Light emitted from a lower epitaxial sub-unit may be configured to be emitted to the outside of the light emitted stacked structure by passing through an upper epitaxial sub-unit disposed on the lower epitaxial sub-unit
Data Source
AI summary
A light emitting diode pixel for a display including a first LED sub-unit, a second LED sub-unit disposed on a first portion of the first LED sub-unit, and a third LED sub-unit disposed on a second portion of the second LED sub-unit, in which each of the first, second, and third LED sub-units includes a first conductivity type semiconductor layer and a second conductivity type semiconductor layer, light generated from the first LED sub-unit is configured to be emitted outside of the light emitting diode pixel through a third portion of the first LED sub-unit different from the first portion, and light generated from the second LED sub-unit is configured to be emitted outside of the light emitting diode pixel through a fourth portion of the second LED sub-unit different from the second portion.