Black Transfer Film Laser Lift-Off for Micro LED Black Matrix Alignment
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Solution Overview
Problem
Existing methods for forming a black matrix in micro LED displays are time-consuming, lack positional accuracy, and struggle to achieve sufficient height to suppress color mixing, and require precise alignment for mounting micro LEDs.
Innovation Solution
A laser lift-off method using a black transfer film with a black transfer layer on a light-transmitting base material is employed to transfer individual pieces of the black matrix to the wiring substrate, followed by deforming the layer to form a black matrix around the micro LEDs and connecting them to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If method (a) is used to form a black matrix by applying composition and removing it via etching or photolithography, then the black matrix can be formed, but the process becomes time-consuming
Solution Approach 1:
The black matrix pattern is extracted and pre-formed on a separate carrier film before being transferred to the display substrate. This separates the black matrix formation process from the substrate processing, eliminating time-consuming etching or photolithography steps on the final substrate while maintaining precise pattern formation.
Solution Approach 2:
The black matrix pattern is prepared in advance on a carrier film using screen printing or other formation methods. This preliminary action allows the black matrix to be ready for transfer without requiring time-consuming processing steps on the display substrate itself, thus reducing overall production time while ensuring precise pattern formation.
2Productivity
If methods (b) or (c) are used to form a black matrix on a carrier film or cover glass, then the process is faster, but positional accuracy is insufficient
Solution Approach 1:
A carrier film serves as an intermediary medium where the black matrix pattern is precisely formed using screen printing or similar methods. This intermediary allows for accurate pattern formation and easy handling, which is then transferred to the display substrate with high positional accuracy, combining the speed of pre-forming with the precision of accurate positioning.
3Ease of operation
If method (d) is used to apply black matrix ink via inkjet after micro LED mounting, then alignment is easier, but the black matrix height is insufficient to suppress color mixing
Solution Approach 1:
The black matrix is formed using screen printing or similar methods that enable precise control of material thickness and height parameters. By adjusting printing pressure, material viscosity, and layer thickness during the pre-forming stage on the carrier film, the black matrix achieves sufficient height to suppress color mixing while maintaining ease of alignment through the transfer process.
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
The method significantly reduces production time, ensures precise positional accuracy, forms a black matrix with sufficient height to prevent color mixing, and achieves accurate alignment of micro LEDs, enhancing the efficiency of the manufacturing process.
Implementation Method 1
a step of applying laser light to the black transfer film from the light-transmitting base material side thereof, thereby transferring individual pieces of the black transfer layer to positions on the wiring substrate
Data Source
AI summary
A producing method for a light-emitting device including a black matrix in at least a part of peripheries of light-emitting elements on a wiring substrate includes: a step of allowing a black transfer film with a black transfer layer formed on one side of a light-transmitting base material to face, from the black transfer layer side, the substrate before the light-emitting elements are disposed; a step of applying laser light to the black transfer film from the base material side, transferring pieces of the black transfer layer to positions on the substrate of the light-emitting elements; and a step of disposing and mounting the light-emitting elements on the pieces of the black transfer layer that have been transferred to the substrate, deforming the black transfer layer to form a black matrix in at least a part of the peripheries of the light-emitting elements and connecting the elements to the substrate.