Holding Substrate Alignment Marks for Dense Display Transfer
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Solution Overview
Problem
Existing display device manufacturing methods reduce the quantity of light-emitting elements per holding substrate due to the need for alignment marks, requiring additional transfer processes to accommodate these marks, which decreases efficiency.
Innovation Solution
A holding substrate is sectioned into first and second sections, with the first sections having a higher light transmission rate than the second sections, forming alignment marks that allow precise alignment with a transfer destination substrate without reducing the number of light-emitting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If alignment marks are formed by creating partial regions with no light-emitting elements on the holding substrate, then alignment between holding substrate and transfer destination substrate is achieved, but the quantity of light-emitting elements per holding substrate is reduced
Solution Approach 1:
The holding substrate is divided into first sections (with light-emitting elements) and second sections (without light-emitting elements). The second sections form alignment marks that do not reduce the quantity of light-emitting elements on the holding substrate, as these non-light-emitting regions are structural divisions rather than wasted space.
2Measurement precision
If alignment marks are provided on the holding substrate, then alignment is enabled, but additional transfer processes are required for light-emitting elements corresponding to the partial region with alignment marks
Solution Approach 1:
By segmenting the holding substrate into first and second sections, the alignment marks are integrated into the substrate structure itself. This allows all light-emitting elements to be transferred in one operation without requiring supplemental transfer processes for alignment mark regions.
3Quantity of substance
If the holding substrate is sectioned into first and second sections with different light transmission rates, then alignment marks are formed without reducing light-emitting element quantity, but the structure becomes more complex
Solution Approach 1:
The holding substrate has different light transmission rates in different regions: first sections have a first light transmission rate and second sections have a second light transmission rate. This local quality difference creates visible alignment marks when light passes through, allowing the substrate to maintain full light-emitting element capacity without requiring additional structural complexity beyond the sectional division.
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 increases the quantity of light-emitting elements per holding substrate by eliminating the need for supplemental transfer processes, enhancing manufacturing efficiency and alignment accuracy.
Implementation Method 1
Each of the first sections is provided in a part of a gap between the second sections when viewed from the one direction, has a light transmission rate higher than a light transmission rate of the second sections, and forms the first alignment mark through which light passes when viewed from the one direction.
Data Source
AI summary
According to an aspect, a manufacturing method of a display device includes: obtaining a first reference position on a surface of a holding substrate based on positions of a plurality of first alignment marks of the holding substrate; and aligning the holding substrate with a transfer destination substrate such that the first reference position on the holding substrate and a second reference position on a surface of the transfer destination substrate coincide. The holding substrate is sectioned into a plurality of first sections and a plurality of second sections when viewed from one direction. Each of the first sections is provided in a part of a gap between the second sections when viewed from the one direction, has a light transmission rate higher than a light transmission rate of the second sections, and forms the first alignment mark through which light passes when viewed from the one direction.