Flexible Barrier Rib Transfer for Large-Area Micro LED Alignment
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Solution Overview
Problem
Existing methods for manufacturing micro LEDs, such as laser lift off and pick and place, result in reduced productivity when micro LEDs become smaller and displays become larger in size.
Innovation Solution
A display transfer structure comprising a base layer with a flexible barrier rib having holes for micro LEDs, where the flexible barrier rib is made of a polymer material with a metal layer, allowing for large-area manufacturing and efficient transfer of micro LEDs onto a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser lift off or pick and place method is used to transfer micro LEDs, then micro LEDs can be transferred, but productivity is reduced when micro LEDs become smaller and displays become larger in size
Solution Approach 1:
The invention segments the transfer process into two distinct stages: first, transferring multiple micro LEDs simultaneously from a first substrate to a flexible barrier rib structure; second, transferring the entire assembly to the final display substrate. This segmentation allows parallel processing of multiple micro LEDs, dramatically improving productivity compared to sequential pick-and-place methods.
Solution Approach 2:
The flexible barrier rib structure serves as an intermediary carrier that temporarily holds multiple micro LEDs in precise positions. This intermediary structure enables simultaneous transfer and positioning of multiple micro LEDs, acting as a bridge between the source substrate and final display substrate, thereby resolving the productivity bottleneck.
2Area of stationary object
If laser lift off or pick and place method is used, then micro LEDs can be transferred, but the process becomes inefficient for large area displays
Solution Approach 1:
The invention transitions from one-dimensional sequential transfer (pick-and-place) to two-dimensional parallel transfer by arranging multiple micro LEDs in a grid pattern on the flexible barrier rib. This dimensional change enables simultaneous positioning of multiple micro LEDs across large display areas, dramatically improving manufacturing efficiency.
Solution Approach 2:
The flexible barrier rib structure is pre-configured with multiple positioning sites and transfer features before micro LEDs are placed. This preliminary preparation allows for rapid, simultaneous transfer of multiple micro LEDs to their final positions, eliminating the need for repeated positioning operations and significantly improving productivity for large area displays.
3Manufacturing precision
If flexible barrier rib with hydrophobic properties is used, then accurate placement and separation of micro LEDs is facilitated, but device complexity increases
Solution Approach 1:
The flexible barrier rib structure utilizes hydrophobic parameter changes in specific regions to achieve selective adhesion and release of micro LEDs. By modifying the surface energy characteristics (hydrophobicity) of specific zones, the structure enables automatic positioning and accurate placement of micro LEDs without complex mechanical positioning systems, thereby improving manufacturing precision while managing device complexity.
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 large-area manufacturing of displays with improved productivity by aligning and transferring micro LEDs efficiently, using a flexible barrier rib with hydrophobic properties to facilitate accurate placement and separation.
Implementation Method 1
An upper surface of the flexible barrier rib may be more hydrophobic than a surface of the base layer exposed by the plurality of holes
Data Source
AI summary
A display transfer structure includes a base layer, a flexible barrier rib positioned on the base layer and having a plurality of holes therein, and a plurality of micro light emitting diodes (LEDs) positioned respectively in the plurality of holes. A method of manufacturing the display transfer structure includes forming a flexible barrier rib having holes on a base layer, supplying liquid to the holes, supplying micro LEDs to the liquid, and scanning the flexible barrier rib with an absorber capable of absorbing the liquid to align each of the micro LEDs in a respective hole such that electrodes of the micro LEDs face an outside of the holes.