Display Element Transfer Using Laser-Released Polymer Intermediary
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Solution Overview
Problem
The adhesion between the stamp film and the light emitting element in display device manufacturing is difficult to uniformly define due to material characteristic variations, leading to a risk of incomplete transfer of the light emitting element on the backplane and increased defect rates in the display device.
Innovation Solution
A method of manufacturing a display device involves manufacturing light emitting elements, disposing them on a moving member with a moving polymer layer, bonding them to a stamp member using a laser to separate the light emitting elements from the moving polymer layer, and transferring them onto a pixel circuit layer using a laser bonding, thermo-compression bonding, or eutectic bonding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a stamp film is used to transfer light emitting elements, then the transfer process can be automated, but the adhesion between the stamp film and light emitting element varies due to material characteristic variation, leading to incomplete transfer
Solution Approach 1:
A moving member with a moving polymer layer is introduced as an intermediary between the light emitting elements and the stamp film. The moving polymer layer provides uniform adhesion properties that enable complete transfer, while the stamp film maintains its automation function. This intermediary resolves the contradiction by decoupling the automation function from the adhesion function.
Solution Approach 2:
The adhesion characteristics are changed by using a moving polymer layer with controlled adhesion strength that can be uniformly adjusted. The laser separation process also changes the adhesion parameter dynamically by reducing adhesion strength at specific locations and times, enabling complete and precise transfer.
2Manufacturing precision
If laser separation is used to separate light emitting elements from the moving polymer layer, then separation precision is improved, but the process complexity increases
Solution Approach 1:
The mechanical separation process is replaced with laser-based separation. The laser provides non-contact, high-precision separation by selectively reducing adhesion strength through optical energy, eliminating the need for complex mechanical separation mechanisms and achieving superior precision.
Solution Approach 2:
The laser separation process utilizes phase transition or chemical change in the moving polymer layer when exposed to laser energy, causing a localized reduction in adhesion strength. This phase change mechanism enables precise separation without complex mechanical systems.
3Manufacturing precision
If multiple light emitting elements of different colors are manufactured on separate growth substrates, then color purity is improved, but the manufacturing time increases
Solution Approach 1:
Multiple light emitting elements of different colors, manufactured on separate growth substrates, are merged onto a single moving member using the moving polymer layer. This consolidation allows subsequent unified processing and transfer operations, reducing the total manufacturing time while maintaining the color purity benefits of separate growth.
Solution Approach 2:
Light emitting elements are preliminarily manufactured on separate growth substrates to ensure color purity, then transferred to the moving member in advance. This preliminary separation allows for optimized growth conditions for each color while enabling efficient subsequent processing.
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 method ensures the transfer stability of light emitting elements, improves process precision, reduces the risk of incomplete transfer, and decreases the defect rate of the display device.
Implementation Method 1
The separating of the light emitting elements may include applying the laser to at least a portion of the moving polymer layer; and decreasing an adhesion between the at least a portion of the moving polymer layer, to which the laser is applied, and the light emitting elements.
Data Source
AI summary
There are provided a method of manufacturing a display device and a display device. The method includes manufacturing light emitting elements; disposing the light emitting elements on a moving member; bonding the light emitting elements and a stamp member to each other; and transferring the light emitting elements on a pixel circuit layer. The moving member includes a moving base and a moving polymer layer on the moving base. The disposing of the light emitting elements includes attaching the light emitting elements on the moving polymer layer. The bonding of the light emitting elements includes separating the light emitting elements and the moving polymer layer from each other, by a laser.