Light-Emitting Element Transfer Alignment for High-Resolution Displays
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Solution Overview
Problem
Existing methods face challenges in fabricating high-resolution display devices with light-emitting elements due to difficulties in accurately supplying and aligning light-emitting elements at the required density and concentration, especially when using inkjet printing equipment.
Innovation Solution
A method involving a transfer device with a printing substrate and stamp is used to prepare and align light-emitting elements, utilizing alignment electrodes and a capping layer to ensure precise placement on a target substrate, allowing for concurrent transfer of elements of varying sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inkjet printing equipment is used to supply light-emitting elements, then the manufacturing process can be simplified, but the alignment precision and placement accuracy deteriorate
Solution Approach 1:
The patent introduces a transfer substrate as an intermediary between the inkjet printing process and the final substrate. The inkjet printer deposits light-emitting elements on the transfer substrate where alignment is easier, then a transfer electrode picks up the elements and places them precisely on the final substrate. This mediator resolves the contradiction by separating the deposition process from the placement process.
Solution Approach 2:
The patent divides the manufacturing process into distinct stages: (1) inkjet deposition on transfer substrate, (2) drying and alignment electrode formation, (3) transfer electrode pickup, and (4) final placement on target substrate. This segmentation allows each stage to be optimized independently, maintaining simplicity in deposition while achieving precision in final placement.
2Manufacturing precision
If light-emitting elements are supplied at high density and concentration, then the resolution of the display device is improved, but the difficulty of accurate supply and alignment increases
Solution Approach 1:
The transfer substrate serves as a mediator that handles the high-density element supply. Elements are deposited at high concentration on the transfer substrate using inkjet printing, then the transfer electrode systematically picks them up and places them on the final substrate. This intermediary manages the complexity of high-density handling while enabling high resolution.
Solution Approach 2:
The patent performs preliminary actions on the transfer substrate before final placement: drying the deposited elements, forming alignment electrodes, and preparing pickup structures. These preliminary steps organize the high-density elements in a controllable manner, reducing the complexity of the final alignment operation.
3Manufacturing precision
If alignment electrodes and capping layers are added to the transfer device, then the alignment precision is improved, but the device complexity increases
Solution Approach 1:
The patent merges the alignment electrode and capping layer functions into the transfer substrate structure. The alignment electrodes are formed on the transfer substrate, and the capping layer is integrated as part of the same structure. This merging reduces overall device complexity by combining multiple functions into a single integrated component rather than adding separate systems.
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 the fabrication of high-resolution display devices by improving the alignment and transfer efficiency of light-emitting elements, reducing damage to underlying structures and enhancing the yield of the display device.
Implementation Method 1
one of the printing substrate and the stamp includes a first alignment electrode, a second alignment electrode, and a capping layer covering the first alignment electrode and the second alignment electrode
Data Source
AI summary
A method of fabricating a display device includes preparing a transfer device including a printing substrate and a stamp; supplying an ink containing light-emitting elements onto the printing substrate; picking up the light-emitting elements with the stamp; and transferring the light-emitting elements to a target substrate, the light-emitting elements being aligned on the printing substrate or the stamp.