Backboard Coil Structures for Micro LED Mass Transfer
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Solution Overview
Problem
The high production cost and difficulty in mass-producing micro LEDs, particularly in achieving a high yield ratio during the transfer process, hinder the widespread adoption of micro LED display technologies.
Innovation Solution
A backboard with LED installation mounts featuring coil structures that generate a magnetic field to precisely position LED pins onto lead-out electrodes, allowing for efficient and mass transfer of LEDs with a high yield ratio, using a method that includes forming metal line patterns with indentations and dielectric layers to create the coil structures and connecting them through via holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If micro LEDs are transferred using conventional methods, then the transfer process can be completed, but the good yield ratio is low and production cost is high
Solution Approach 1:
The patent replaces conventional mechanical transfer methods with a magnetic field-based positioning system. Coil structures generate magnetic fields that interact with magnetic beads attached to LED pins, enabling non-contact positioning and attachment. This substitution eliminates mechanical contact issues and improves both transfer efficiency and yield ratio.
Solution Approach 2:
The patent introduces magnetic beads as intermediary elements between the LED pins and the coil structures. These magnetic beads serve as mediators that transmit magnetic field forces to precisely position the LED pins on the lead-out electrodes, enabling accurate alignment without direct mechanical intervention.
2Manufacturing precision
If conventional transfer methods are used, then LEDs can be transferred, but positioning precision is insufficient
Solution Approach 1:
The patent changes the physical parameter of positioning from mechanical force to magnetic field interaction. By adjusting coil current and magnetic field strength, the system achieves precise control over LED pin positioning while maintaining high transfer speeds through automated control.
Solution Approach 2:
The patent attaches magnetic beads to LED pins in advance before the transfer process. This preliminary action prepares the LEDs for magnetic field-based positioning, enabling rapid and precise alignment during the transfer operation without requiring complex real-time adjustment mechanisms.
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
Enables precise and efficient transfer of LEDs onto the backboard with a high good yield ratio, reducing production costs and facilitating mass production of micro LED display devices.
Implementation Method 1
a coil structure around each of the at least two lead-out electrodes, wherein the coil structure is configured to produce a magnetic field upon being powered on
Data Source
AI summary
The disclosure discloses a backboard, a display device, and a method for fabricating the same, and the backboard includes: a backboard body; and a plurality of LED installation mounts arranged in an array on the backboard body, wherein each of the plurality of LED installation mounts includes at least two lead-out electrodes to be connected with LED pins, and a coil structure around each of the at least two lead-out electrodes, wherein the coil structure is configured to produce a magnetic field upon being powered on. The coils can be formed on the backboard body in the backboard to absorb electrodes of LEDs to thereby position them precisely so as to transfer the LEDs in a mass manner with a high good yield ratio, and the lead-out electrodes can be powered on to thereby detect abnormally operating LEDs.