LED-Powered Ink Curing for MicroLED Display Substrates
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Solution Overview
Problem
The manufacture of microLED displays is inefficient and expensive, particularly in providing colored pixels, due to challenges in curing light-curable ink on substrates with light-emitting diodes (LEDs).
Innovation Solution
An apparatus with a light-sealable housing and a transfer device is used to supply power to LEDs on a substrate, ensuring efficient curing of light-curable ink by illuminating it with specific wavelengths, while maintaining a stable temperature and inert atmosphere to prevent unspecific curing and improve yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional UV curing chambers with external UV sources are used, then curing can be achieved, but the process becomes complex and less efficient
Solution Approach 1:
The patent combines the LED light source and the curing function into a single integrated component. The LEDs that emit light for display purposes also serve as the curing source for the encapsulant material, eliminating the need for separate UV curing chambers and external curing sources, thus simplifying the device structure while improving curing efficiency
Solution Approach 2:
The LED serves multiple functions: it acts as both the light source for the microLED display and the curing source for the encapsulant material. This multi-functionality reduces the number of components needed and streamlines the manufacturing process by combining illumination and curing operations
2Productivity
If external UV curing sources are used, then curing can be achieved, but energy consumption increases and process becomes less efficient
Solution Approach 1:
The patent merges the curing function with the LED light source itself, eliminating the need for separate high-energy UV curing sources. The LEDs provide both display illumination and curing energy, reducing overall energy consumption while improving manufacturing efficiency
Solution Approach 2:
The LED light source serves itself by using its emitted light to cure the encapsulant material. This self-service approach eliminates the need for external curing sources and reduces energy consumption by utilizing the light already generated for display purposes
3Productivity
If LEDs are illuminated to cure the ink, then curing efficiency improves, but temperature control becomes critical to prevent unspecific curing
Solution Approach 1:
The patent introduces an inert atmosphere (nitrogen or sulfur hexafluoride) into the sealing plate chamber during the curing process. This inert environment prevents unspecific curing and chemical reactions that could be triggered by temperature fluctuations, while allowing the LEDs to efficiently cure the encapsulant material
Solution Approach 2:
The patent changes the atmospheric parameters by introducing inert gases (nitrogen or sulfur hexafluoride) to control the chemical environment during curing. This parameter change prevents unwanted side reactions and stabilizes the curing process, allowing efficient LED illumination without compromising temperature stability
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 enhances curing efficiency, reduces unspecific curing, and achieves higher yields by using self-curing LEDs, improving the manufacturing process for microLED displays with precise and energy-efficient results.
Implementation Method 1
An apparatus with a light-sealable housing and a transfer device is used to supply power to LEDs on a substrate, ensuring efficient curing of light-curable ink by illuminating it with specific wavelengths
Implementation Method 2
curing light-curable ink by illuminating it with specific wavelengths
Implementation Method 3
maintaining a stable temperature and inert atmosphere to prevent unspecific curing and improve yield
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
An apparatus (100) including a light-sealable housing (105) for curing light-curable ink printed on a substrate (10) having light emitting diodes (LEDs) is provided. The apparatus includes a substrate support (130), an interface (110) for supplying power to the LEDs and a transfer device (120) configured to change a relative position of the interface and the substrate support (130). The5 transfer device (120) is configured to bring the interface (110) into contact with the substrate (10) for providing the power to the LEDs for illuminating the LEDs to cure the light-curable ink.