Intermediate Substrate With Black Photoresist for LED Display Transfer
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Solution Overview
Problem
The fabrication process of light emitting diode (LED) display panels is complex, costly, and inefficient due to the separate steps of transferring light emitting diodes, forming a black matrix, and connecting them to driving circuits, leading to issues like crosstalk and color mixing.
Innovation Solution
An intermediate substrate with a black photoresist layer and light emitting devices is used, allowing simultaneous transfer and electrical connection to a driving substrate, integrating the black matrix formation in a single process, thereby simplifying the fabrication and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light emitting diodes are transferred separately and black matrix is formed in separate steps, then manufacturing precision can be maintained, but device complexity and fabrication process complexity increase significantly
Solution Approach 1:
The patent combines the transfer of light emitting diodes and the formation of the black matrix into a single integrated process. The black matrix material is applied as a layer covering the entire substrate, and during the same pressing and heating operation that transfers the LEDs from the temporary substrate, the black matrix is simultaneously formed in the gaps between LEDs. This merging of operations reduces fabrication process complexity while maintaining alignment precision through the use of alignment marks and controlled pressing mechanisms.
2Manufacturing precision
If multiple separate fabrication steps are used for transferring LEDs and forming black matrix, then manufacturing precision is maintained, but productivity decreases
Solution Approach 1:
The patent implements continuous useful action by performing the LED transfer and black matrix formation in a single uninterrupted pressing and heating operation. The black matrix material is already positioned on the substrate before the pressing step, so when the LEDs are transferred by pressing and heating, the black matrix is simultaneously formed without requiring separate processing steps. This continuity eliminates idle time between operations and significantly improves fabrication efficiency while maintaining transfer accuracy through controlled pressing parameters.
3Manufacturing precision
If separate transfer and black matrix formation steps are used, then manufacturing precision can be ensured, but loss of time increases
Solution Approach 1:
The patent merges the transfer operation and black matrix formation into a single simultaneous process. The black matrix material is applied to cover the substrate before the transfer step, and during the pressing and heating operation that transfers LEDs from the temporary substrate, the black matrix is concurrently formed in the gaps between adjacent LEDs. This merging eliminates the sequential execution of separate steps, reducing total fabrication time while maintaining alignment accuracy through integrated process control and alignment marks.
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 simplifies the fabrication process, reduces costs, and improves efficiency by combining the transfer of light emitting devices and black matrix formation into a single step, while preventing crosstalk and color mixing.
Implementation Method 1
a black photoresist layer, wherein a light-exiting side of each of the plurality of light emitting devices is in contact with the black photoresist layer
Data Source
AI summary
Embodiments of the present disclosure provide an intermediate substrate, including: a first substrate; a black photoresist layer on a side of the first substrate; and a plurality of light emitting devices on a side of the black photoresist layer away from the first substrate. Each of the plurality of light emitting devices has a light-exiting side for emergence of light emitted by the light emitting device, the light-exiting side is in contact with the black photoresist layer, and the light emitting device includes a driving electrode for introducing a driving signal.