Vertical Micro-LED Stack Structure for High-Density Pixels
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Solution Overview
Problem
Conventional display technologies, such as LCDs and OLEDs, face limitations in achieving high-resolution displays due to the horizontal arrangement of micro-LEDs, which occupy significant space and hinder manufacturing of high-density pixels.
Innovation Solution
A vertically stacked electronic device is developed by stacking multiple micro-LEDs in a vertical direction, with a common electrode and individual electrodes penetrating through each micro-LED, along with a method that includes providing a protective film and using laser irradiation for precise etching to form a high-density pixel configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro-LEDs are arranged horizontally to form pixels, then the display can be manufactured using conventional processes, but the horizontal space occupied by each pixel limits the resolution and pixel density
Solution Approach 1:
The patent transitions from a two-dimensional horizontal arrangement of micro-LEDs to a three-dimensional vertical stacking configuration. Multiple micro-LEDs are stacked vertically to form a single pixel, utilizing the vertical dimension to increase pixel density without proportionally increasing the horizontal area occupied by each pixel. This dimensional change enables higher resolution displays while maintaining manageable pixel footprints.
2Manufacturing precision
If multiple micro-LEDs are stacked vertically to increase pixel density, then high-resolution displays can be achieved, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The patent divides each pixel into multiple vertically stacked segments, where each segment contains one or more micro-LEDs. This segmentation allows independent control and optimization of each vertical segment, enabling the complex vertical structure to be managed through modular design. Each segment can be manufactured and tested separately before assembly, reducing overall manufacturing complexity.
Solution Approach 2:
The patent implements a common electrode structure that serves multiple functions: it provides electrical connection to multiple micro-LEDs in the vertical stack, acts as a shared control line for multiple pixel segments, and enables unified addressing of vertically stacked LEDs. This multi-functionality reduces the number of separate components needed, simplifying the overall device architecture despite the vertical stacking complexity.
3Reliability
If a common electrode penetrates through multiple micro-LEDs in the vertical stack, then electrical connection to all LEDs is achieved, but the risk of short circuits increases
Solution Approach 1:
The patent introduces an insulating layer as an intermediary between the common electrode and the micro-LEDs in the vertical stack. This insulating layer is selectively removed at specific regions to create contact holes that allow electrical connection while maintaining insulation in other areas. The intermediary layer prevents unintended electrical contact and short circuits between the common electrode and adjacent micro-LEDs, ensuring reliable but controlled electrical connections.
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
This approach enables the creation of high-density pixels by saving horizontal space, allowing for the implementation of high-resolution displays while preventing short circuits through precise etching of the protective film using a laser.
Implementation Method 1
the protective film, where the pad electrode is located, may be selectively irradiated with a laser
Data Source
AI summary
Proposed is a vertically stacked electronic device that enables the implementation of high-resolution displays by stacking individual LEDs vertically, and a method for manufacturing the vertically stacked electronic device.