Conductive Carrier Electrostatic Transfer for LED Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in the field of electronic device manufacturing lies in efficiently and accurately transferring miniaturized LED elements to a target substrate, as the adhesive force of sacrificial layers can exceed the electrostatic force of attraction, leading to failures in picking up the elements during the transfer process.
Innovation Solution
The method involves using a conductive carrier with an insulating layer to hold the electronic elements, setting the carrier to a reference voltage during the picking process to control charges and improve transfer efficiency and accuracy, and employing a transfer device with conductive heads to generate an electrostatic force for selective picking up of the elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sacrificial layer is used to hold electronic elements on the conductive carrier, then the elements can be temporarily positioned, but the adhesive force of the sacrificial layer becomes greater than the electrostatic force of attraction, causing failure to pick up the elements
Solution Approach 1:
The patent removes the sacrificial layer entirely from the process and replaces it with a conductive carrier that directly holds the electronic elements through controlled electrostatic forces. This extraction of the sacrificial layer eliminates the adhesive force problem while maintaining the temporary positioning function through voltage-controlled electrostatic attraction between the conductive carrier and the elements.
Solution Approach 2:
The patent replaces the mechanical/adhesive bonding mechanism of the sacrificial layer with an electrostatic field-based holding mechanism. By applying voltage to the conductive carrier, electrostatic forces are generated to hold the electronic elements without requiring adhesive materials, thus avoiding the adhesive force that prevented element pickup.
2Productivity
If the conductive carrier is used to hold electronic elements, then transfer efficiency can be improved, but residual charges on the carrier may interfere with the picking up process
Solution Approach 1:
The patent employs periodic voltage application to the conductive carrier - applying voltage to hold elements during transfer, then removing or adjusting the voltage to release elements at the target substrate. This periodic control of the electrostatic field ensures both efficient transfer and accurate pickup by timing the electrostatic attraction and release phases appropriately.
Solution Approach 2:
The patent controls the electrostatic forces by dynamically changing the voltage parameter on the conductive carrier. By adjusting the voltage level and timing, the system optimizes both the holding force during transfer and the release characteristics at the target, managing residual charges through parameter control rather than physical modifications.
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 reduces the risk of element failure during transfer, enhances the efficiency and accuracy of transferring miniaturized LED elements to the target substrate, and improves the overall yield by managing electrostatic forces and residual charges.
Implementation Method 1
the electrostatic force of attraction between the transfer heads and the electronic elements
Implementation Method 2
by controlling the charges of electronic elements by the conductive structures of the conductive carrier
Data Source
AI summary
A method of manufacturing an electronic device includes the steps of providing a conductive carrier with at least one electronic element disposed thereon, picking up the at least one electronic element, setting the conductive carrier to have a ground voltage at least in the step of picking up the at least one electronic element, and transferring the at least one electronic element to a target substrate.