Patent ID: 8642363

Claim:
A method for manufacturing a monolithic Light Emitting Diode (LED) micro-display panel on an Active Matrix (AM) panel, the LED microarray panel comprising a plurality of LED pixels each including an n-electrode and a p-electrode, with the LED pixels arranged in a matrix including a plurality of rows and a plurality of columns, n-electrodes of LED pixels in a row of the matrix, electrically connected to a bus line, the p-electrode of each LED pixel individually electrically connected to an output of a corresponding driving circuit on the AM panel, the method comprising: providing a substrate of the LED micro-display panel; overlaying a plurality of layers of material on a surface of the substrate, with the plurality of overlaying layers of material configured in combination to emit light when activated; patterning the plurality of overlaying layers of material by removing a part of each overlaying layers all the way down to the surface of the substrate; depositing a current spreading layer on the patterned plurality of overlaying layers of material and surface of the substrate; providing a metal multilayer on the current spreading layer; patterning the metal multilayer in such a configuration that a first portion of the metal multilayer, which lies on the patterned plurality of overlaying layers of material, and a second portion of the metal multilayer, which lies on the surface of the substrate, and conductively disconnected from the substrate, thereby forming the monolithic LED micro-display panel; providing a plurality of active control circuits on a surface of the AM panel; and combining the monolithic LED micro-display panel with the AM panel using conductive solder material, with each of the monolithic LEDs electrically insulated from one another and independently controllable by corresponding ones of the active control circuit chips bonded thereto, with the plurality of active control circuits combined with the monolithic LEDs in such a way that each of the plurality of active control circuits combine with one of the monolithic LEDs of the LED microarray panel via the solder material, wherein the AM panel, pixel size and shape correspond to LED pixels.