MICRO LED STRUCTURE AND MICRO LED PANEL

Abstract

A micro LED structure and a full color micro LED panel provided by the disclosure comprises: at least three mesa structures. A first dielectric layer is formed between the first connecting layer and the second connecting layer, the third connecting layer is shared by the second mesa structure and the third mesa structure. The micro LED structure can improve the light emitting efficiency and reduce the cross talk between the adjacent micro LEDs.

Description

FIELD OF THE DISCLOSURE

The present disclosure generally relates to micro light-emitting diode (LED) manufacturing technology and, more particularly, to a micro LED structure and a micro LED panel using the micro LED structure.

BACKGROUND OF THE DISCLOSURE

Inorganic micro light-emitting diodes are also called “micro LEDs.” They are increasingly important because of their use in various applications including, for example, self-emissive micro-displays, visible light communications, and opto-genetics. The micro LEDs have greater output performance than conventional LEDs, due to better strain relaxation, improved light extraction efficiency, uniform current spreading, etc. Moreover, compared with the conventional LEDs, the micro LEDs have improved thermal effects, improved operation at higher current density, better response rate, greater operating temperature range, higher resolution, higher color gamut, higher contrast, lower power consumption, etc.

A micro LED panel is manufactured by integrating an array of thousands or even millions of micro LEDs with a driver circuitry back panel. Each pixel of the micro LED panel is formed by one or more micro LEDs. The micro LED panel can be a mono-color or multi-color panel. In particular, for a multi-color LED panel, each pixel may further include multiple sub-pixels respectively formed by multiple micro LEDs, each of which corresponds to a different color. For example, three micro LEDs respectively corresponding to red, green, and blue colors may be superimposed to form one pixel. The different colors can be mixed to produce a broad array of colors.

The existing micro LED technology, however, faces several challenges. For example, one challenge is to improve the effective illumination area within each pixel when the distance between the adjacent LEDs is determined. Moreover, when a single LED illumination area is determined, further improving the overall resolution of the micro LED panel can be a difficult task because micro LEDs with different colors have to occupy their designated zones within the single pixel.

Additionally, the light emitted by the LED dies is generated from spontaneous emission and is thus not directional, resulting in a large divergence angle. The large divergence angle can cause various problems in a micro-LED panel. On one hand, due to the large divergence angle, only a small portion of the light emitted by the micro-LEDs can be utilized. This may significantly reduce the efficiency and brightness of a micro-LED display system. On the other hand, due to the large divergence angle, the light emitted by one micro-LED pixel may illuminate its adjacent pixels, resulting in light crosstalk between pixels, loss of sharpness, and loss of contrast.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure provides a micro LED structure that addresses the problems in the related art, such as the problems described above. In particular, the disclosed micro LED structure integrates two or more vertically stacked micro LEDs, by placing them at different layers of the micro LED structure and electrically connecting them to an integrated circuit (IC) back panel. The micro LED structure effectively enhances the light illumination efficiency within a single pixel area, and at the same time, improves the resolution of the micro LED panel.

Moreover, the disclosed micro LED structure further improves the light illumination efficiency by including reflection layers that not only effectively increase the amount of light emitted by each of the vertically stacked micro LEDs, but also reduce crosstalk between the vertically stacked micro LEDs.

Consistent with the disclosed embodiments, a plurality of the disclosed micro LED structures can be arranged in a micro LED array to form a micro LED panel. Each of the plurality of micro LED structures corresponds to a pixel of the disclosed micro LED structure, and the multiple vertically stacked micro LEDs in a pixel correspond to multiple sub-pixels respectively.

In some embodiments, the disclosed micro LED structure comprises an IC back plane, a stack of mesa structures comprising a first mesa structure and a second mesa structure, and a dielectric layer between the first and second mesa structures.

In some embodiments, the first mesa structure may be on the IC back plane and comprise a first light emitting layer, a first top connecting layer formed on and electrically connected to the first light emitting layer, and a conductive bonding layer formed under the first light emitting layer and electrically connecting the first light emitting layer to the IC back plane.

In some embodiments, the second mesa structure may be on the first mesa structure and comprise a second light emitting layer, a second top connecting layer formed on and electrically connected to the second light emitting layer, a second conductive bonding layer formed under the second light emitting layer, and a second bottom connecting layer formed under the second conductive bonding layer and electrically connected to the second light emitting layer via the second conductive bonding layer.

In some embodiments, the first mesa structure may not have a second connecting layer, in that the first conductive bonding layer may bound the first light emitting layer to the IC back plane.

In some embodiments, a third mesa structure may be stacked on top of the second mesa structure. The third mesa structure may comprise the same layers as the second mesa structure does, except that the third mesa structure does not have a third in bottom connecting layer. The third light emitting layer may be electrically connected to the second top connecting layer from its top instead.

In some embodiments, each of the light emitting layers comprises a P type semiconductor layer, a N type semiconductor layer, and a quantum well layer between the P type semiconductor layer and the N type semiconductor layer. For example, each of the light emitting layers may comprise a P type semiconductor layer at the bottom and an N type semiconductor layer on the top, thereby forming a P-N junction; or alternatively, each of the light emitting layers may comprise an N type semiconductor layer on the bottom and a P type semiconductor layer on the top, thereby forming an N-P junction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a cross sectional view of a micro LED structure, according to some embodiments of the present disclosure;

FIG. 1B is a top view of an exemplary micro LED structure, according to some embodiments of the present disclosure;

FIG. 1C is a top view of another exemplary micro LED structure, according to some embodiments of the present disclosure;

FIG. 1D is a top view of an exemplary micro LED panel, according to some embodiments of the present disclosure;

FIG. 1E is a top view of another exemplary micro LED panel, according to some embodiments of the present disclosure:

FIG. 2 is a cross sectional view of another micro LED structure, according to some embodiments of the present disclosure:

FIG. 3 is a cross sectional view of another micro LED structure, according to some embodiments of the present disclosure:

FIG. 4 is a cross sectional view of another micro LED structure, according to some embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to exemplary embodiments to provide a further understanding of the disclosure. The specific embodiments and the accompanying drawings discussed are merely illustrative of specific ways to make and use the disclosure, and do not limit the scope of the disclosure or the appended claims.

FIG. 1A is a cross-sectional view of a micro LED structure 10, according to some embodiments of the present disclosure. As shown in FIG. 1A, the micro LED structure 10 comprises an IC back plane 900 and three mesa structures. Specifically, among the three mesa structures, a first mesa structure comprises, from bottom up, a first conductive bonding layer 103, a first light emitting layer 100 (e.g., layer emitting light in red color), and a first top connecting layer 101. The first top connecting layer 101 is electrically connected to the top of the first light emitting layer 100, and the first conductive bonding layer 103 bonds the bottom of the first light emitting layer 100 to the IC back plane 900. A second mesa structure of the micro LED structure 10 comprises, from bottom up, a second bottom connecting layer 202, a second conductive bonding layer 203, a second light emitting layer 200 (e.g., layer emitting light in green color), and a second top connecting layer 201. The second top connecting layer 201 is electrically connected to the top of the second light emitting layer 200, and the second bottom connecting layer 202 electrically connects the bottom of the second light emitting layer 200 to the IC back plane 900. A third mesa structure of the micro LED structure 10 comprises, from bottom up, a third conductive bonding layer 303, a third light emitting layer 300 (e.g., layer emitting light in blue color), and a third top connecting layer 301. The second top connecting layer 201 bonds and electrically connects to the third light emitting layer 300. The three mesa structures are stacked on the IC back plane 900, with the second mesa structure being formed above the first mesa structure, and the third mesa structure being formed above the second mesa structure. On the IC backplane 900 there may be contact pads (e.g., 901, 902, 903), each of which provides electrical signals to the first, second, or third mesa structure, respectively.

Continuing referring to FIG. 1A, in some embodiments, dielectric material 700 may be filled between the top connecting layer 101 and the bottom connecting layer 202, and thus form a dielectric layer 701 between the first top connecting layer 101 and the second bottom connecting layer 202. In some embodiments, the dielectric material 700 may be filled in gaps of the micro LED structure 10, thereby isolating the light emitting layers (e.g., the light emitting layers 100, 200, 300) from being electrically connected with each other.

In some embodiments, the light emitting layers 100, 200, 300 may emit light or light images in different colors. In some exemplary embodiments, the first light emitting layer 100 is chosen as a red color light emitting layer, the second light emitting layer 200 is chosen as a green color light emitting layer, and the third light emitting layer 300 is chosen as a blue color light emitting layer. The above color assignment is for illustrative purpose only. Consistent with the disclosed embodiments, other combinations of light colors may be assigned to the light emitting layers to obtain any needed result.

When vertically projecting the mesa structures of the micro LED structure 10 onto a horizontal plane, each of the mesa structure forms a projective area on the horizontal plane. Each projective area on the horizontal planes has an outline, which is herein referred to as projective outline in plan view (i.e., top view). In some embodiments, the disclosed micro LED structure is configured to make an upper light emitting layer's projective outline in plan view located within a lower light emitting layer's projective shape in plan view., thereby forming multiple mesa structures with different widths. Specifically, FIG. 1B is a top view of the micro LED structure 10 of FIG. 1A. As shown in FIG. 1B, R, G, B respectively represent the areas of the light emitting layers 100, 200, 300 formed in top view. In this exemplary embodiment, the projective outline of the light emitting layer 300 is located within the projective outline of the light emitting layer 200; and the projective outline of the light emitting layer 200 is located within the outline of the light emitting layer 100.

Referring back to FIG. 1A, in the exemplary embodiment illustrated therein, the sidewalls of the conductive bonding layers 103, 203, 303 are respectively aligned with the sidewalls of the light emitting layer 100, 200, 300. Specifically, the sidewalls of the conductive bonding layer 103 are aligned with the sidewalls of the light emitting layer 100; the sidewalls of the conductive bonding layer 203 are aligned with the sidewalls of the light emitting layer 200; and the sidewalls of the conductive bonding layer 303 are aligned with the sidewalls of the light emitting layer 300.

In some embodiments, the conductive bonding layers may be transparent or opaque. In some embodiments, the material of the conductive bonding layers is selected from one of a metal, a composite metal, or a transparent conductive material. In some embodiments, the transparent conductive material may be made of transparent plastic (resin) or silicon dioxide (SiO₂), e.g., spin-on glass (SOG), bonding adhesive Micro Resist BCL-1200, etc. The metal may be selected from copper (Cu), gold (Au), etc. In some embodiments, the thickness of the conductive bonding layers (e.g., 103, 203, 303) can range from about 0.1 micron to about 5 microns. In some embodiments, metal compositions for the bonding layers may include Au—Au bonding, Au—Sn bonding, Au—In bonding, Ti—Ti bonding, Cu—Cu bonding, or a combination thereof. For example, when Au—Au bonding is needed, the two layers of Au each need a chrome (Cr) coating as an adhesive layer, and platinum (Pt) coating between the gold layer and the chrome coating as an anti-diffusion layer. The Cr and Pt layers may be formed on both Au layers to be bonded. In some embodiments, when the thicknesses of the two Au layers to be bonded are about the same, the mutual diffusion of Au on both Au layers may bond the two layers together under high pressure and high temperature. Example bonding techniques may include eutectic bonding, thermal compression bonding, and transient liquid phase (TLP).

In some embodiments, the material of the top connecting layers 101, 201, 301 and the bottom connecting layer 202 may be selected from a transparent conductive material. In some embodiments, the transparent conductive material may be Indium Tin Oxide (ITO). In some embodiments, the thickness of the ITO layer can range from about 0.01 micron to about 1 micron.

In some embodiments, the second and third mesa structures are bonded by the second top connecting layer 201. The sidewalls of the second top connecting layer 201 may be aligned with the second light emitting layer and considered as a layer of the second mesa structures. In other words, the second and third light emitting layers 200 and 300 both electrically connect to the second top connecting layer 201. In some embodiments, the second light emitting layer 200 may have its entire area covered by the second top connecting layer 201 and therefore have its entire area utilized.

In some embodiments, a common connecting layer through via 400 filled with conductive metal may be formed next to the light emitting layers 100, 200, 300, and next to the stack of mesa structures. In some exemplary embodiments, as shown in FIG. 1A, the common connecting layer through via 400 is electrically connected to the light emitting layers 100, 200, 300 via the top connecting layers 101, 201. In some embodiments, a top contact pad 401 may be formed on the top of the common connecting layer through via 400. The top contact pad 401 can be electrically connected to circuitry outside the micro LED structure 10.

In some embodiments, at least one of anode connecting layer through vias 500, 600 may be formed next to the stacked mesa structures of micro LED structure 10. The anode connecting layer through vias 500, 600 are formed at positions that are separate from the position of the common connecting layer through via 400. For example, the anode connecting layer through vias 500, 600 may be positioned on a different side of the mesa structures from the common connecting layer through via 400. The through vias 400, 500, 600 are not electrically connected to each other.

In one exemplary embodiment, as shown in FIG. 1A, the anode connecting layer through via 500 connects the light emitting layer 200 to the IC back plane 900, via the second bottom connecting layer 202. And the anode connecting layer through via 600 connects the light emitting layer 300 to the IC back plane 900, via the top connecting layer 301. In this exemplary embodiment, the first light emitting layer 100 is electrically connected to the IC back plane 900 via the conductive bonding layer 103, and therefore no connecting layer through via is needed to connect the first light emitting layer 100 to the IC back plane 900.

FIG. 1B schematically illustrates a top view of the micro LED structure 10 of FIG. 1A, according to an exemplary embodiment. The dotted rectangles represent the bottom connecting layers 202 and 302, respectively. For purpose of better explaining the relevant structural features, other layers are not shown in FIG. 1B. As shown in FIG. 1B, the top contact pad 401 is formed on the opposite side of the mesa structures to the anode connecting layer through vias 500, 600. The anode connecting layer through vias 500, 600 are formed in a direction perpendicular to adjacent edges of the mesa structures.

FIG. 1C schematically illustrates a top view of the micro LED structure 10 of FIG. 1A, according to another exemplary embodiment. As shown in FIG. 1C, The anode connecting layer through vias 500, 600 are formed in a direction parallel to adjacent edges of the mesa structures. The embodiments in FIGS. 1B and 1C are for illustrative purpose only. The common connecting layer through via and the anode connecting layer through vias may be formed at any position in a micro LED area.

FIG. 1D is a top view of a micro LED panel 11, according to an exemplary embodiment. As shown in FIG. 1D, the micro LED panel 11 includes an array of micro LED structures 10. As shown in FIG. 1D, the top contact pads 401 of the multiple micro LED structures 10 in each row are connected together to form a continuous line. A shared contact pad 402 connects all the rows of the top contact pads 401 together. In this exemplary embodiment, the distributed direction of the anode connecting layer through vias 500, 600 is perpendicular to the distributed direction of the top contact pad 401.

FIG. 1E is a top view of a micro LED panel 11, according to another exemplary embodiment. As shown in FIG. 1E, the adjacent rows of micro LEDs share one top contact pad 401. This arrangement further increases the integration level of the micro LED panel.

In some embodiments, each mesa structures may further comprise a reflection layer. The reflection layer in each mesa structure may be formed at the bottom surface of the respective light emitting layer or at the bottom surface of the respective conductive bonding layer. Moreover, the reflection layer may be formed between the mesa structures, e.g., between the bottom connecting layer of a higher mesa structure and the top connecting layer of a lower mesa structure. These embodiments are described below in detail in connection with FIGS. 2-4.

FIG. 2 is a cross sectional view of a micro LED structure 20, according to some exemplary embodiments. The micro LED structure 20 is a variation of the micro LED structure 10 (FIG. 1A). The same numbers in FIGS. 1A and 3 refer to the same structures, the details of which are not repeated herein. Only the differences between FIGS. 1A and 2 are explained below. As shown in FIG. 2, at least one mesa structures may have a reflection layer (e.g., 104, 204, 304) formed at the bottom surface of its light emitting layer (e.g., 100, 200, 300). For example, reflection layers 104, 204, 304 are formed at the bottom surfaces of the light emitting layers 100, 200, 300, respectively. The sidewalls of the reflection layers 104, 204, 304 are aligned with the sidewalls of the light emitting layers 100, 200, 300 in the mesa structures, respectively. For example, in the bottom mesa structure, the reflection layer 104 is formed at the bottom surface of the light emitting layer 100 and the sidewall of the reflection layer 104 is aligned with the sidewall of the light emitting layer 100; in the middle mesa structure, the reflection layer 204 is formed at the bottom surface of the light emitting layer 200 and the sidewall of the reflection layer 204 is aligned with the sidewall of the light emitting layer 200; and in the top mesa structure, the reflection layer 304 is formed at the bottom surface of the light emitting layer 300 and the sidewall of the reflection layer 304 is aligned with the sidewall of the light emitting layer 300. In some embodiments, a reflection layer in the micro LED structure 20 comprises stacked transparent layers and metal omnidirectional reflection (ODR) layers, stacked distributed Bragg reflection (DBR) layers, or high-reflectivity metal. In some embodiments, the thickness of the reflection layer ranges from about 0.1 micron to about 5 microns.

In some embodiments, a reflection layer (e.g., 104, 204, or 304) may be an insulating layer (e.g., dielectric DBR layer). A sidewall connecting layer may be added to provide electrical continuity between light emitting layers (e.g., 100, 200, 300) and conductive bonding layers (e.g., 103, 203, 303). For example, sidewall connecting layer 310 may provide electrical connection between light emitting layer 300 and conductive bonding layer 303. A similar sidewall connecting layer may be added to the first and/or second mesa structure as needed.

FIG. 3 is a cross sectional view of a micro LED structure 30, according to some exemplary embodiments. The micro LED structure 30 is a variation of the micro LED structure 10 (FIG. 1A). The same numbers in FIGS. 1A and 3 refer to the same structures, the details of which are not repeated herein. Only the differences between FIGS. 1A and 3 are explained below. As shown in FIG. 3, reflection layers 105, 205, 305 are formed at the bottom surfaces of the conductive bonding layers 103, 203, 303, respectively. Similarly, the sidewalls of the reflection layers 105, 205, 305 are aligned with the sidewalls of the conductive bonding layers 103, 203, 303 in the mesa structures, respectively. For example, in the bottom mesa structure, the reflection layer 105 is formed at the bottom surface of the conductive bonding layer 103 and the sidewall of the conductive bonding layer 103 is aligned with the sidewall of the corresponding reflection layer 105: in the middle mesa structure, the reflection layer 205 is formed at the bottom surface of the conductive bonding layer 203 and the sidewall of the conductive bonding layer 203 is aligned with the sidewall of the corresponding reflection layer 205; and in the top mesa structure, the reflection layer 305 is formed at the bottom surface of the conductive bonding layer 303 and sidewall of the conductive bonding layer 303 is aligned with the sidewall of the corresponding reflection layer 305. In some embodiments, each of the reflection layers in the micro LED structure 30 comprises stacked transparent layers and metal ODR layers, stacked DBR layers, or high-reflectivity metal.

In some embodiments, a reflection layer (e.g., 105, 205, or 305) may be an insulating layer (e.g., dielectric DBR layer). A sidewall connecting layer may be added to provide electrical continuity between light emitting layers (e.g., 100, 200, 300) and connecting layers or IC backplane (e.g., 201, 202, 900). For example, sidewall connecting layer 310 may provide electrical connection between light emitting layer 300 and second top connecting layer 201. A similar sidewall connecting layer may be added to the first and/or second mesa structure as needed.

FIG. 4 is a cross sectional view of a micro LED structure 40, according to some embodiments of the present disclosure. The micro LED structure 40 is a variation of the micro LED structure 10 (FIG. 1A). Comparing to FIG. 1A, the same numbers in FIG. 4 refer to the same structures, the details of which are not repeated herein. Only the differences from FIG. 4 are explained below. As shown in FIG. 4, a transparent reflection layer (e.g., 106 or 206) is formed on top of the top connecting layers (e.g., 101, 201). For example, between the top connecting layer of the first mesa structure and the bottom connecting layer of the second mesa structure, and between the top connecting layer of the second mesa structure and the third conductive bonding layer 303. In this exemplary embodiment, the sidewalls of the transparent reflection layer 106, 206 may be aligned with the sidewalls of the light emitting layer of the second and third mesa structure (e.g., 200, 300, respectively). That is, the transparent reflection layer 106 is formed on the first top connecting layer 101 and at the bottom of the second bottom connecting layer 202 of the middle mesa structure, and the sidewalls of the transparent reflection layer 106 are aligned with the sidewalls of the light emitting layer 200 of the second mesa structure; the transparent reflection layer 206 is formed on the second top connecting layer 201 and at the bottom of the third conductive bonding layer 303 of the top mesa structure, and the sidewalls of the transparent reflection layer 206 are aligned with the sidewalls of the light emitting layer 300 of the third mesa structure. The transparent reflection layers 106, 206 reflects light emitted from the respective lower light emitting layer (e.g., 100, 200, respectively). For example, upward light (e.g., red light) emitted from the light emitting layer 100 is reflected by the transparent reflection layer 106, which has higher reflectivity than the conductive bonding layer 203. Similarly, upward light (e.g., green light) emitted from the light emitting layer 200 is reflected by the transparent reflection layer 206, which has higher reflectivity than the conductive bonding layer 303.

In some embodiments, a reflection layer (e.g., 106, 206) may be an insulating layer (e.g., dielectric DBR layer). A sidewall connecting layer may be added to provide electrical continuity between light emitting layers (e.g., 200, 300) and connecting layers (e.g., 101, 201). For example, sidewall connecting layer 310 may provide electrical connection between light emitting layer 300 and second top connecting layer 201. A similar sidewall connecting layer may be added to the second mesa structure as needed.

In some embodiments, the above-described reflection layers each may comprise a distributed Bragg reflector (DBR) structure. For example, the reflection layers may be formed by stacking multiple layers of alternating or different materials with varying refractive index. In some embodiments, each layer boundary of the DBR structure may cause a partial reflection of an optical wave. In some embodiments, a reflection layer is made of multiple layers of SiO₂ and Ti₃O₅. In some embodiments, a reflection layer is made of multiple layers of Au and/or Indium Tin Oxide (ITO). By manipulating the thicknesses and/or numbers of layers of SiO₂ and Ti₃O₅, or by manipulating the thicknesses and/or numbers of layers of Au and/or and ITO, selective reflection or transmission of light at specific wavelengths may be achieved. For example, in an exemplary design, the reflection layer 106 in FIG. 4 reflects red light; and the reflection layer 206 in FIG. 4 reflects green light. For example, the following DBR structure shown in Table I can be used in a reflection layer to reflect green light from a green light emitting layer:

TABLE 1
DBR layer structure for a green light reflection layer.
Layer composition Layer thickness (in nanometer)
SiO2              1000
TiO2              109.54
SiO2              318.48
TiO2              64.95
SiO2              106.07
TiO2              245.76
SiO2              137.08
TiO2              65.14
SiO2              106.77
TiO2              338.95
SiO2              37.27
TiO2              12.41
SiO2              352.18
TiO2              70.83
SiO2              229.25
ITO               20

In some embodiments, the reflection layer 204 for a green light LED structure may have a low absorbance (e.g., equal to or less than 5%) of the light generated by different layers of the tri-color LED device. In some embodiments, the reflection layer 204 for a green light layer has a high reflectance (e.g., equal to or more than 95%) of the light generated above itself, e.g., green light and blue light.

In some exemplary embodiments, the first light emitting layer 100 in the micro LED structure 10 (FIG. 1A), 20 (FIG. 2), 30 (FIG. 3), or 40 (FIG. 4) is designed to emit red light. Examples of a red light emitting layer include III-V nitride, III-V arsenide, III-V phosphide, and III-V antimonide epitaxial structures. In some embodiments, films within the red light emitting layer may include layers of P-type (Al)(In)(Ga)P/P-type (Al)InGaP light-emitting layer/N-type (Al)(In)(Ga)P/N-type GaAs. In some embodiments, P type may be Mg-doped or carbon-doped, and N-type may be Si-doped. In some embodiments, the thickness of the light emitting layer 100 may range from about 0.3 micron to about 5 microns.

In some embodiments, the second light emitting layer 200 in the micro LED structure 10 (FIG. 1A), 20 (FIG. 2), 30 (FIG. 3), or 40 (FIG. 4) is designed to emit green light. Examples of a green light emitting layer include III-V nitride, III-V arsenide, III-V phosphide, and III-V antimonide epitaxial structures. In some embodiments, films within the green light emitting layer 200 may include the layers of P-type GaN/InGaN light-emitting layer/N-type GaN. In some embodiments, P type may be Mg-doped, and N-type may be Si-doped. In some embodiments, the thickness of the light emitting layer 200 may range from about 0.3 micron to about 5 microns.

In some embodiments, the light emitting layer 300 in the micro LED structure 10 (FIG. 1A), 20 (FIG. 2), 30 (FIG. 3), or 40 (FIG. 4) is designed to emit blue light. Examples of a blue light emitting layer include III-V nitride, III-V arsenide, III-V phosphide, and III-V antimonide epitaxial structures. In some embodiments, films within the blue light emitting layer 300 may include the layers of P-type GaN/InGaN light-emitting layer/N-type GaN. In some embodiments, P type may be Mg-doped, and N-type may be Si-doped. In some embodiments, the thickness of the blue light emitting layer 300 may range from about 0.3 micron to about 5 microns.

In some embodiments, in the micro LED structure 10 (FIG. 1A), 20 (FIG. 2), 30 (FIG. 3), or 40 (FIG. 4), the connecting layer on the very top of the micro-LED structure (e.g., the third top connecting layer 302) is deposited on the light emitting layer 300. In some embodiments, the thickness of the third top connecting layer 302 (ITO layer) may be from about 0.01 micron to about 1 micron.

In some embodiments, a micro lens 800 may be formed on top of a micro LED structure (e.g., the micro LED structures as shown in FIGS. 1A, and 2-4).

The micro LEDs described in the disclosed embodiments have a very small size in volume. The micro LED may be an organic LED or an inorganic LED. In some embodiments, the micro LED may be applied in a micro LED array panel. The light emitting area of the micro LED array panel may be very small, e.g., 1 mm×1 mm, 3 mm×5 mm, etc. In some embodiments, the light emitting area may be the area of the micro LED array in the micro LED array panel. The micro LED array panel may include one or more micro LED arrays, which form a pixel array in which the micro LEDs are pixels, e.g., a 1600×1200, 680×480, or 1920×1080 pixel array. The diameter of the micro LED may be in the range of about 200 nm˜2 μm. In some embodiments, an IC backplane may be formed at the back surface of the micro LED array and electrically connected to the micro LED array. In some embodiments, the IC backplane may acquire signals, such as, for example, image data from outside via signal lines, to control the on/off of the corresponding micro LEDs (e.g., emitting light or not).

Accordingly, different types of display panels may be fabricated. For example, in some embodiments, the resolution of a display panel may range from 8×8 to 3840×2160. Common display resolutions include QVGA with 320×240 resolution and an aspect ratio of 4:3, XGA with 1024×768 resolution and an aspect ratio of 4:3, D with 1280×720 resolution and an aspect ratio of 16:9, FHD with 1920×1080 resolution and an aspect ratio of 16:9, UHD with 3840×2160 resolution and an aspect ratio of 16:9, and 4K with 4096×2160 resolution and an aspect ratio of 1.9. There can also be a wide variety of pixel sizes, ranging from sub-micron and below to 10 mm and above. The size of the overall display region can also vary widely, ranging from diagonals as small as tens of microns or less up to hundreds of inches or more.

It is understood by those skilled in the art that, the micro LED display panel is not limited by the structure mentioned above, and may include more or less components than those as illustrated, or some components may be combined, or a different component may be utilized.

It should be noted that, the relational terms herein such as “first” and “second” are used only to differentiate an entity or operation from another entity or operation, and do not require or imply any actual relationship or sequence between these entities or operations. Moreover, the words “comprising,” “having,” “containing,” and “including,” and other similar forms are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.

As used herein, unless specifically stated otherwise, the term “or” encompasses all possible combinations, except where infeasible. For example, if it is stated that a database may include A or B, then, unless specifically stated otherwise or infeasible, the database may include A, or B, or A and B. As a second example, if it is stated that a database may include A, B, or C, then, unless specifically stated otherwise or infeasible, the database may include A, or B, or C, or A and B, or A and C, or B and C, or A and B and C.

It is understood by those skilled in the art that, all or part of the steps for implementing the foregoing embodiments may be implemented by hardware or may be implemented by a program that instructs related hardware. The program may be stored in the aforementioned flash memory, in the aforementioned conventional computer device, in the aforementioned central processing module, in the aforementioned adjustment module, etc.

The above descriptions are merely embodiments of the present disclosure, and the present disclosure is not limited thereto. A modifications, equivalent substitutions and improvements made without departing from the conception and principle of the present disclosure shall fall within the protection scope of the present disclosure.

Claims

1. A micro LED structure, comprising: an IC back plane;a first mesa structure formed on the IC back plane, the first mesa structure comprising a first connecting layer;a first dielectric layer formed on the first mesa structure;a second mesa structure formed on the first dielectric layer, the second mesa structure comprising a second connecting layer and a third connecting layer; anda third mesa structure formed on the third connecting layer, the third mesa structure comprising a fourth connecting layer;wherein the second connecting layer and the fourth connecting layer are electrically connected with the IC back plane;wherein the first connecting layer is electrically connected to the third connecting layer;wherein the third connecting layer is electrically connected to a bottom surface of the third mesa structure; andwherein each of the first, second, and third mesa structures comprises: a first epitaxial layer having a first conductive type;a quantum well layer on the first epitaxial layer; anda second epitaxial layer on the quantum well layer, the second epitaxial layer having a second conductive type.

2. The micro LED structure of claim 1, wherein the first, second, and third mesa structures respectively form a first outline, a second outline, and a third outline in plan view, the third outline being disposed within the second outline, the second outline being disposed within the first outline.

3. The micro LED structure of claim 2, further comprising: a first bonding layer formed under the first mesa structure, the first bonding layer bonding a bottom surface of the first mesa structure to the IC back plane;a second bonding layer formed between the second connecting layer and the rest of the second mesa structure, the second bonding layer bonding a bottom surface of the rest of the second mesa structure to the second connecting layer; anda third bonding layer formed between the third connecting layer and the rest of the third mesa structure, the third bonding layer bonding the bottom surface of the rest of the third mesa structure to the third connecting layer.

4. The micro LED structure of claim 3, wherein: a sidewall of the first bonding layer is aligned with a sidewall of the first mesa structure;a sidewall of the second bonding layer is aligned with a sidewall of the second mesa structure; anda sidewall of the third bonding layer is aligned with a sidewall of the third mesa structure.

5. The micro LED structure of claim 3, wherein each of the first, second, and third bonding layers comprises: a metal;a composite metal; ora transparent conductive material.

6. The micro LED structure of claim 5, wherein the transparent conductive material is silicon dioxide (SiO2) or indium tin oxide (ITO).

7. The micro LED structure of claim 3, wherein the first dielectric layer comprises a first reflection layer.

8. The micro LED structure of claim 7, wherein the transparent conductive material is indium tin oxide (ITO).

9. The micro LED structure of claim 7, wherein a sidewall of the first reflection layer is aligned with a sidewall of the second mesa structure.

10. The micro LED structure of claim 9, wherein the first reflection layer comprises: stacked transparent layers;metal omnidirectional refection (ODR) layers;stacked distributed Bragg reflection (DBR) layers; orhigh-reflectivity metal.

11. The micro LED structure of claim 9, wherein the first reflection layer is electrically insulative.

12. The micro LED structure of claim 7, wherein the first reflection layer, the first connecting layer, and the second connecting layer are transparent.

13. The micro LED structure of claim 7, further comprising a second reflection layer formed between the third connecting layer and the third bonding layer.

14. The micro LED structure of claim 13, wherein a sidewall of the second reflection layer is aligned with a sidewall of the third mesa structure.

15. The micro LED structure of claim 14, wherein the second reflection layer comprises: stacked transparent layers and metal omnidirectional refection (ODR) layers;stacked distributed Bragg reflection (DBR) layers; ora high-reflectivity metal.

16. The micro LED structure of claim 13, wherein the second reflection layer and the third connecting layer are transparent.

17. The micro LED structure of claim 13, wherein the second reflection layer is electrically insulative.

18. The micro LED structure of claim 13, further comprising a sidewall connecting structure on the third connecting layer, wherein the sidewall connecting structure is formed next to and configured to connect a sidewall of the second reflection layer and a sidewall of the third bonding layer.

19. The micro LED structure of claim 1, wherein each of the first, second, and third connecting layers comprises a transparent conductive material.

20. The micro LED structure of claim 1, further comprising a first through via formed next to one or more of the first, second, and third mesa structures, the first through via being electrically connected to the first connecting layer and the third connecting layer.

21. The micro LED structure of claim 20, further comprising a second through via and a third through via formed next to one or more of the first, second, and third mesa structures, wherein the second through via connects the second connecting layer to the IC back plane and the third through via connects the fourth connecting layer to the IC back plane.

22. The micro LED structure of claim 1, wherein: the first conductive type is a P type semiconductor, andthe second conductive type is an N type semiconductor.

23. The micro LED structure of claim 1, wherein: the first conductive type is an N type semiconductor, andthe second conductive type is a P type semiconductor.

24. A full color micro LED panel, comprising a micro LED array, the micro LED array comprises a plurality of micro LED structures, wherein each of the plurality of micro LED structures comprises: an IC back plane;a first mesa structure formed on the IC back plane, the first mesa structure comprising a first connecting layer;a first dielectric layer formed on the first mesa structure;a second mesa structure formed on the first dielectric layer, the second mesa structure comprising a second connecting layer and a third connecting layer; and a third mesa structure formed on the third connecting layer, the third mesa structure comprising a fourth connecting layer;wherein the second connecting layer and the fourth connecting layer are electrically connected with the IC back plane;wherein the first connecting layer is electrically connected to the third connecting layer;wherein the third connecting layer is electrically connected to a bottom surface of the third mesa structure; andwherein each of the first, second, and third mesa structures comprises: a first epitaxial layer having a first conductive type;a quantum well layer on the first epitaxial layer; anda second epitaxial layer on the quantum well layer, the second epitaxial layer having a second conductive type.