Magnetic LED Transfer Substrate for Precise Display Panel Alignment
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Solution Overview
Problem
Transferring a large number of small light emitting elements, such as LEDs, to a receiving substrate is challenging due to their miniaturized size and the need for precise alignment and magnetic attraction.
Innovation Solution
A method involving a first electromagnetic plate with magnetically charged through holes to attract and align light emitting elements from a carrier substrate, and a receiving substrate with a second magnetic material layer to ensure accurate transfer and attachment, utilizing control circuits to manage magnetic forces for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If light emitting elements are miniaturized to increase density, then the number of elements per unit area increases, but the difficulty of transferring and aligning them increases
Solution Approach 1:
A magnetic plate is introduced as an intermediary carrier between the source substrate and receiving substrate. The magnetic plate temporarily holds the miniaturized light emitting elements through magnetic attraction, enabling precise positioning and transfer without direct mechanical handling. This mediator resolves the contradiction by providing magnetic control for high-precision alignment while handling large quantities of small elements
Solution Approach 2:
The patent replaces traditional mechanical transfer methods with magnetic field-based manipulation. Instead of using mechanical grippers or alignment tools that struggle with miniaturized elements, the invention uses magnetic fields to attract, position, and transfer the light emitting elements, achieving both high quantity handling and precise alignment
2Manufacturing precision
If traditional transfer methods are used, then the process is simple, but the transfer accuracy and efficiency decrease
Solution Approach 1:
The magnetic plate serves multiple functions: it acts as a carrier substrate, a positioning tool, a transfer mechanism, and an alignment reference all in one component. This multi-functionality achieves high transfer accuracy without proportionally increasing system complexity, as the same magnetic plate performs multiple critical operations in the transfer process
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
Enables the efficient transfer and alignment of a large quantity of light emitting elements with improved accuracy, reducing transfer errors and ensuring proper placement on the receiving substrate, facilitating the assembly of display panels.
Implementation Method 1
the first electromagnetic plate is energized to magnetically adsorb one light emitting element from the carrier substrate at each adsorption position
Implementation Method 2
the first electromagnetic plate and the receiving substrate are moved towards each other so that each of the light emitting elements magnetically adsorbed on the first electromagnetic plate is aligned one-to-one with a corresponding receiving area on the receiving substrate
Implementation Method 3
the second electromagnetic plate is powered on to form a magnetic field between the first magnetic material layer of each light emitting element and the second magnetic material layer, and the first electromagnetic plate is powered off so that each of the light emitting elements is detached from the first electromagnetic plate by the magnetic field
Data Source
AI summary
A substrate and a display panel using the substrate are disclosed. The substrate includes a base layer; a magnetic material layer on a side of the base layer; and a thin film transistor (TFT) array layer on a side of the magnetic material layer away from the base layer.