Stacked Micro-LED Pixel Structure for High-Brightness Displays
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Solution Overview
Problem
Existing micro-LED display devices face challenges in maintaining high brightness and resolution due to limitations in arranging micro-LED elements per unit area, issues with defective elements, and interference between pixels, which also increase power consumption.
Innovation Solution
A method of manufacturing an LED display device by aligning micro-LED elements parallel to the substrate plane and stacking them perpendicular to the substrate, using grooves and connection electrodes to connect them to electrode layers, allowing for efficient integration and connection of multiple elements without increasing pixel area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If micro-LED elements are arranged horizontally on the substrate, then the device structure is simple, but the brightness and resolution are limited due to the constraint on the number of elements per unit area
Solution Approach 1:
The patent transitions from a two-dimensional horizontal arrangement of micro-LED elements to a three-dimensional stacked structure. Multiple micro-LED elements are arranged vertically in stacks, with each stack containing multiple elements positioned at different heights above the substrate. This vertical stacking enables a significantly increased number of light-emitting elements within the same pixel area, thereby enhancing brightness without expanding the horizontal pixel footprint.
2Illumination intensity
If more micro-LED elements are arranged per unit area to improve brightness, then the brightness increases, but the interference phenomenon between pixels increases
Solution Approach 1:
By arranging micro-LED elements in vertical stacks with spacing between elements, the patent reduces horizontal density while maintaining high total element count. The vertical separation and strategic positioning minimize lateral light spread and crosstalk between adjacent pixels, thereby reducing interference phenomena while preserving high brightness output.
Solution Approach 2:
The patent divides each pixel into multiple discrete micro-LED elements arranged in vertical stacks. Each element is independently positioned and can be selectively activated. This segmentation allows for precise control of light emission from each element, enabling interference mitigation through selective element activation while maintaining overall high brightness.
3Manufacturing precision
If micro-LED elements are stacked vertically to increase element density, then the brightness and resolution improve, but the manufacturing complexity increases
Solution Approach 1:
The patent employs preliminary positioning structures such as protrusions on the substrate or lower layers that correspond to recesses or features on the micro-LED elements. These pre-formed guiding features enable automatic alignment during the stacking process, ensuring precise vertical and lateral positioning of each element without requiring complex real-time adjustment mechanisms during assembly.
Solution Approach 2:
The patent introduces intermediary connection structures such as connection electrodes, insulating layers, and bonding interfaces that facilitate the stacking process. These intermediary elements provide mechanical support, electrical connection, and alignment references between stacked micro-LED elements, simplifying the overall manufacturing process while maintaining high positioning precision.
4Reliability
If defective micro-LED elements occur in horizontally arranged pixels, then the resolution is reduced, but with stacked structure, defective pixels can still function
Solution Approach 1:
By dividing each pixel into multiple independent micro-LED elements arranged in vertical stacks, the patent enables selective activation of functional elements. If one element in a stack is defective, the other elements in the same stack can still be activated to maintain pixel functionality. This segmentation provides redundancy and fault tolerance, improving overall pixel reliability.
Solution Approach 2:
The patent enables dynamic control of individual micro-LED elements within each stack through independent electrical connections. The system can dynamically select and activate only the functional elements while bypassing defective ones, allowing the pixel to adapt its operation based on the actual functional state of its constituent elements, thereby maintaining reliability despite manufacturing variations.
Data Source
AI summary
A light emitting diode (LED) display device includes: a first electrode layer and a second electrode layer disposed to be spaced apart from each other on a substrate; a plurality of micro-LED elements stacked in a longitudinal direction to be parallel to a plane of the substrate on the first electrode layer and the second electrode layer and stacked to be spaced apart from each other; and a first connection electrode coupled to both ends of the plurality of micro-LED elements and extending from one ends of the plurality of micro-LED elements to the first electrode layer and a second connection electrode extending from the other ends of the plurality of micro-LED elements to the second electrode layer and connected to the second electrode layer.