Laser Transfer Head for Clean Bonding of Display Light-Emitting Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display panel fabrication methods face challenges in transferring and bonding light-emitting elements without contamination and defects, particularly due to issues with transfer members and the direct contact of flux with laser transmitters.
Innovation Solution
An apparatus and method utilizing a transport member with a laser transmitter and disposable transfer members to transfer and bond light-emitting elements onto a circuit substrate, where the transfer member includes a stamp layer with adhesiveness and a base layer that transmits laser light, allowing for simultaneous transfer and bonding while preventing contamination of the laser transmitter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a transfer member is used to transfer light-emitting elements, then the transfer process can be performed, but the transfer member may become contaminated with flux causing transfer defects
Solution Approach 1:
The patent employs a disposable transfer member that is discarded after a single use. This eliminates the problem of flux contamination accumulating on reusable transfer members, as each new transfer member starts clean. The transfer member includes a stamp layer with adhesiveness for bonding light-emitting elements and a base layer that transmits laser light, and it is disposed of after one transfer operation to prevent any contamination issues.
Solution Approach 2:
The patent extracts the contaminated component (transfer member) from the system after a single use. By removing the transfer member from the process after one operation, the source of potential contamination is eliminated, preventing flux from being transferred back to the light-emitting elements or circuit substrate in subsequent operations.
2Productivity
If the laser transmitter directly contacts the flux during bonding, then bonding can be performed, but the laser transmitter becomes contaminated
Solution Approach 1:
The patent introduces the transfer member as an intermediary between the laser transmitter and the flux. The transfer member's base layer is transparent to laser light, allowing the laser transmitter to heat and bond the light-emitting elements without direct contact with the flux. This intermediary layer prevents flux contamination of the laser transmitter while enabling the bonding process to proceed effectively.
Solution Approach 2:
The transfer member includes a thin base layer that is transparent to laser light. This thin film structure allows laser energy to pass through while providing a physical barrier that prevents flux from contacting the laser transmitter. The thin film maintains flexibility for the bonding process while protecting the laser transmitter from contamination.
3Ease of manufacture
If a reusable transfer member is used, then cost is reduced, but transfer defects occur due to contamination
Solution Approach 1:
The patent adopts a disposable transfer member strategy where the cost of a single-use transfer member is lower than the cost of dealing with transfer defects. By using inexpensive, single-use transfer members, the system avoids costly rework, scrap, and maintenance associated with contaminated reusable transfer members, achieving better overall cost efficiency despite the apparent waste.
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 efficient transfer and bonding of light-emitting elements with reduced contamination risks and defects, improving the processing convenience and maintaining the integrity of the laser transmitter by using disposable transfer members that do not adhere to the flux.
Implementation Method 1
a laser transmitter formed of a material that transmits laser light
Implementation Method 2
applying laser light to the bonding members through the laser transmitter and the transfer member
Implementation Method 3
a head chuck disposed on a surface of the transport head to surround the side surfaces of the laser transmitter, having an adsorption function
Implementation Method 4
a transfer member having adhesiveness or stickiness that bonds to light-emitting elements; The transfer member may include a stamp layer, that has adhesiveness or stickiness
Data Source
AI summary
The disclosure provides an apparatus for fabricating a display panel. The display device includes a transfer member having adhesiveness or stickiness and thereby capable of being bonded to light-emitting elements and a transport member transferring and bonding the light-emitting elements which are aligned on a donor substrate onto a circuit substrate by the transfer member, the transport member includes a laser transmitter formed of a material capable of transmitting laser light, a transport head capable of moving vertically and horizontally and surrounding side surfaces of the laser transmitter, and a head chuck disposed on a surface of the transport head to surround the side surfaces of the laser transmitter, having an adsorption function, and capable of being attached to, or detached from, the transfer member.