Tiled MicroLED Display Layout for Yield-Stable Large Panels
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Solution Overview
Problem
Current display technologies, such as LCD and OLED, face limitations in brightness, power efficiency, and manufacturing yield, especially for larger direct-view applications like VR headsets and wearables, while microLED displays with silicon backplanes can be costly and non-competitive due to yield reduction as size increases.
Innovation Solution
The use of tiled or tile-able microLED displays, where each tile is independently fabricated and tested, allowing for flexible configuration and rapid design of various sizes and shapes by arranging tiles on a PCB, rather than redesigning the entire silicon die and microLED array for each application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If microLED displays with silicon backplanes are constructed for physically larger applications, then display size increases, but manufacturing yield continually reduces
Solution Approach 1:
The display is divided into multiple independently fabricated and tested tiles that can be assembled to form larger displays. Each tile is manufactured separately on silicon backplanes, allowing for higher yield in smaller units, then combined to achieve the desired large display area without sacrificing manufacturing reliability.
2Adaptability or versatility
If the display size gets larger, then more applications become accessible, but manufacturing yield continually reduces making some applications cost-prohibitive
Solution Approach 1:
By segmenting the display into standard-sized tiles, the system can be scaled to different application requirements by varying the number of tiles used. This modular approach maintains manufacturing efficiency and cost-effectiveness across different display sizes and application types.
Solution Approach 2:
The tiled display architecture provides a universal platform that can be configured for various applications (VR headsets, wearables, monitors, televisions) using the same tile design, eliminating the need for application-specific redesign and reducing per-unit manufacturing costs.
3Device complexity
If LCD displays are used, then display construction is simplified, but power is dissipated for every pixel whether the pixel is on or off
Solution Approach 1:
The microLED display uses periodic scanning to drive pixels, where each pixel is activated only during its designated time slot rather than continuously. This time-multiplexed approach significantly reduces power consumption compared to LCDs, as power is supplied only when pixels need to be displayed, while maintaining a relatively simple construction.
Data Source
AI summary
Displays, systems, and methods may be utilized in applications including, but not limited to, projectors, head-up displays, and augmented reality (AR), mixed reality (MR), and virtual reality (VR) systems or devices, such as headsets or other near-eye devices or systems. Tiled or Tile-able displays and methods, in accordance with the present invention, provide displays of varying sizes, and as such, a Tiled or Tile-able display is configured to accommodate the display size needed for various wearable and mobile devices that require or incorporate displays.