Stacked Pixel Structures for High-Resolution iLED Displays
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Solution Overview
Problem
Existing inorganic light-emitting diode (iLED) displays face challenges in achieving high resolution due to the size constraints of control circuits and light-emitting diodes, which limits their performance and efficiency compared to other display technologies like LCDs and OLEDs.
Innovation Solution
The solution involves a micro-assembled pixel structure where inorganic light-emitting diodes and pixel control devices are separated and distinct, with the iLEDs being micro-transfer printed onto a pixel control device, allowing for a more compact and efficient design. This includes using monocrystalline silicon circuits and separate substrates for iLEDs and pixel controllers, enabling higher resolution and improved performance by reducing the pixel area over the display substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If inorganic light-emitting diodes and pixel control devices are integrated in the same layer on the display substrate, then the display can be constructed with a simpler structure, but the pixel area becomes too large to achieve high resolution
Solution Approach 1:
The patent transitions from a planar integration approach to a vertical stacked architecture. The iLED device and pixel control device are positioned in different layers (first layer and second layer respectively) along the vertical direction, allowing both components to occupy the same horizontal pixel area while maintaining functional separation. This vertical stacking enables high-resolution displays by minimizing the horizontal footprint of each pixel.
Solution Approach 2:
The patent implements a nested structure where the pixel control device is positioned directly over the iLED device in the vertical direction, with the iLED device nested within the horizontal footprint of the pixel control device. This nesting arrangement allows the larger pixel control device to encompass the smaller iLED device, maximizing space utilization and achieving compact pixel structures suitable for high-resolution displays.
2Manufacturing precision
If the size of control circuits and light-emitting diodes is reduced to increase resolution, then manufacturing costs increase and there are limits to further size reduction
Solution Approach 1:
By moving to vertical stacking in different layers, the patent allows each component (iLED and pixel control device) to maintain larger individual sizes while the overall pixel footprint remains small. This vertical arrangement eliminates the need to continuously shrink component sizes horizontally, thereby avoiding the associated increases in manufacturing complexity and costs.
3Manufacturing precision
If OLED light emitters are placed in a layer over the pixel circuits in top-emitting displays, then resolution is less limited by circuit size, but the substrate area must still be shared between circuits and light-emitters
Solution Approach 1:
The patent implements vertical stacking where the iLED device is in a first layer and the pixel control device is in a second layer positioned over the first layer. This vertical arrangement allows both the light-emitting component and the control circuitry to occupy the same horizontal substrate area without interfering with each other, effectively doubling the space utilization efficiency and enabling higher resolution displays.
Data Source
AI summary
A micro-transfer printed high-resolution inorganic light-emitting diode (iLED) display includes a display substrate and a plurality of pixels disposed over the display substrate, each pixel including a pixel controller disposed or formed in or on a pixel substrate and controlling one or more iLEDs disposed or formed in or on respective iLED substrates. The one or more iLEDs are disposed above or below the pixel controller in a separate layer from the pixel controller. The display substrate, the iLED substrate(s), and the pixel substrate are all separate, independent and distinct, and the one or more iLEDs and pixel controller are each separate devices.