Dual-Mask Opening Layout for Circular Micro LED Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in manufacturing display panels with micro LEDs is efficiently transferring these elements from a semiconductor substrate to a display panel substrate while accommodating various panel shapes, particularly circular cells, which existing methods struggle to address effectively.
Innovation Solution
A mask member comprising first and second masks with angled, symmetrical opening patterns and light-blocking layers, along with a transfer device using a laser to precisely align and transfer micro LEDs onto target substrates, allowing for accurate placement on circular cell areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing transfer methods are used, then transfer process is simple, but circular cell shapes cannot be effectively accommodated
Solution Approach 1:
The mask member is divided into a first mask and a second mask that can be positioned at different angles relative to each other. Each mask contains opening patterns that, when overlapped, define the transfer area. This segmentation allows the system to accommodate circular cell shapes by adjusting the angular relationship between the two masks, while keeping individual mask structures relatively simple.
Solution Approach 2:
The invention introduces an angular dimension to the mask configuration by allowing the second mask to be positioned at a specific angle relative to the first mask. This angular arrangement enables the overlapping opening patterns to define circular or curved transfer areas, adding dimensional flexibility without complicating the basic mask structure.
2Manufacturing precision
If opening patterns are disposed at angles, then circular cell transfer precision is improved, but mask alignment complexity increases
Solution Approach 1:
The opening patterns in the first and second masks are arranged asymmetrically at specific angles relative to each other. This asymmetric angular arrangement allows the overlapping patterns to define circular transfer areas with high precision, while the asymmetry itself becomes the solution rather than a complication.
Solution Approach 2:
The second mask contains opening patterns that are essentially a rotated copy of the first mask's patterns. By positioning the second mask at a specific angle, the overlapping region of these copied patterns defines the precise circular transfer area, achieving high precision through pattern repetition rather than complex alignment mechanisms.
3Measurement precision
If multiple masks with opening patterns are used, then transfer area definition precision is improved, but device structure complexity increases
Solution Approach 1:
The first mask and second mask are combined to form a single mask member assembly that works together to define the transfer area. The opening patterns from both masks overlap to create the final transfer region definition, merging their functions to achieve high precision without requiring each individual mask to be overly complex.
Solution Approach 2:
By introducing the angular dimension between the first and second masks, the invention enables precise definition of circular transfer areas through the overlapping opening patterns. This angular arrangement adds a dimensional aspect that improves precision while maintaining relatively simple mask structures.
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 efficient and precise transfer of micro LEDs onto circular cell areas within display panels, enhancing the manufacturing process for display devices.
Implementation Method 1
a laser emitting member, a support member disposed under the laser emitting member and supporting a target substrate
Data Source
AI summary
A mask member, a light emitting element transfer device, and a transfer method are provided. A mask member includes a first mask including a light blocking pattern layer and a base layer, wherein the light blocking pattern layer of the first mask includes a plurality of opening patterns, and a second mask including a light blocking pattern layer and a base layer, wherein the light blocking pattern layer of the second mask includes a plurality of opening patterns disposed at angles relative to a center of the second mask. The mask member defining a transfer area by overlapping an opening pattern of the plurality of opening patterns of the first mask and an opening pattern of the plurality of opening patterns of the second mask.