C2-Symmetric Micro-LED Layout for Accurate Wave-Energy Transfer
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Solution Overview
Problem
Conventional LED chip transfer methods, such as pick-and-place and fluidic assembly, face challenges in accurately orienting and positioning micro-LED chips due to their small size and symmetry issues, leading to uncontrollable transfer and low efficiency, especially when distinguishing between upper, lower, left, and right areas, which complicates the manufacturing of display devices.
Innovation Solution
A C2 symmetrical LED device with a substrate patterned to distinguish between upper, lower, left, and right areas, featuring electrodes positioned symmetrically to match upon 180-degree rotation, combined with a method using wave energy to orient and position the chips accurately through a wave generator device, ensuring precise placement and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pick-and-place or fluidic assembly schemes are used to transfer micro-LED chips, then chip transfer can be performed, but the transfer speed is very low and transfer accuracy is poor due to uncontrollable transfer of small chips
Solution Approach 1:
The patent introduces C2 symmetrical patterns (asymmetric features) on the micro-LED chip substrate including directional arrows, triangular patterns, and electrode arrangements that break the rotational symmetry. This allows the chip to be distinguished from different orientations, enabling accurate positioning and orientation during transfer processes, thereby improving both transfer speed and positioning accuracy simultaneously.
2Reliability
If the substrate is patterned in C2 symmetrical manner with distinguished upper, lower, left, and right areas, then electrode matching is achieved even after 180-degree rotation, but the device complexity increases
Solution Approach 1:
The patent divides the substrate into distinct quadrants (upper, lower, left, right areas) with specific C2 symmetrical patterns in each region. The electrode arrangements are segmented to correspond with these quadrants, allowing systematic orientation control while maintaining manageable complexity through modular pattern design.
Solution Approach 2:
Different C2 symmetrical patterns are applied to different local regions of the substrate (upper, lower, left, right areas) with specific electrode configurations in each quadrant. This local differentiation enables orientation identification without requiring complete redesign of the entire substrate, balancing reliability improvement with controlled complexity.
3Ease of manufacture
If conventional square or rectangular wafer patterning is used, then processing is easy, but the upper, lower, left, and right areas cannot be distinguished, making accurate display device manufacturing difficult
Solution Approach 1:
The patent modifies the conventional square/rectangular wafer pattern by introducing C2 symmetrical asymmetric features (directional arrows, triangular patterns, non-uniform electrode spacing) that maintain ease of fabrication while providing clear orientation cues. These asymmetric elements break the rotational symmetry of conventional designs, enabling accurate orientation identification without significantly complicating the manufacturing 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
This approach enables efficient and accurate transfer of micro-LED chips, ensuring electrode matching even after rotation, thereby enhancing the manufacturing process for mini-LED and micro-LED displays by excluding defective chips and improving transfer speed.
Implementation Method 1
a method for arranging C2 symmetrical LED devices using wave energy
Data Source
AI summary
Disclosed is a LED device in which a plane of a substrate is patterned in a C2 symmetrical manner such that upper, lower, left, and right areas thereof are distinguished from each other. Further, in positioning the electrodes, one conductivity-type electrode is positioned on a center of the substrate, and electrodes of a conductivity-type different from that of the center electrode are positioned in an opposite manner to each other around the center electrode and are spaced from the center electrode by the same distance. Thus, even when the LED device is rotated by 180 degrees, the electrodes may match with each other. Further, disclosed are a method arranging C2 symmetrical LED devices using wave energy, and a method for fabricating a display module using the arranged C2 symmetrical LED devices. The C2 symmetrical LED device has the 180 degrees rotation symmetry. Thus, upper, lower, left, and right areas thereof are distinguished from each other, and thus, the devices may be oriented very accurately.