Micro LED Alignment via Shape-Matched Grooves
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Solution Overview
Problem
The existing methods for aligning micro light emitting elements, such as the pick and place method and self-assembly, face challenges with low productivity and high misalignment/damage rates due to the small size of micro LEDs and the large size of displays, leading to reduced yield and increased process time.
Innovation Solution
A method involving a substrate with grooves of different shapes to accommodate micro light emitting elements of varying shapes and postures, allowing for precise alignment by matching the unique dimensions and orientations of each element, thereby increasing transfer yield and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pick and place method is used to transfer micro LEDs, then micro LEDs can be transferred onto substrate, but productivity is low due to small size of micro LEDs and large size of display
Solution Approach 1:
The substrate is divided into multiple regions with different groove patterns, allowing simultaneous transfer of multiple micro LEDs in different orientations. The display area is segmented into zones that can be filled independently, increasing overall transfer efficiency
Solution Approach 2:
The invention introduces orientation diversity by allowing micro LEDs to be transferred in multiple directions (first direction and second direction perpendicular to first direction). This dimensional approach enables more efficient space utilization on the large display substrate, reducing the number of transfer cycles needed
2Reliability
If micro LEDs are transferred using conventional methods, then transfer can be completed, but misalignment and damage rates are high
Solution Approach 1:
Different regions of the substrate have locally optimized groove patterns tailored to specific transfer requirements. Each region can accommodate micro LEDs with specific orientations, ensuring precise alignment and reducing misalignment rates during the transfer process
Solution Approach 2:
The groove structure serves as an intermediary element that guides and positions micro LEDs during transfer. The grooves act as mechanical guides that ensure proper orientation and placement, reducing both misalignment and damage rates
3Area of stationary object
If micro LEDs are transferred to large area display, then display can be manufactured, but productivity decreases due to size mismatch
Solution Approach 1:
The large display area is segmented into multiple transfer zones with different groove orientations. This allows parallel processing of different regions, maintaining high productivity even as display area increases. Each zone can be independently optimized for its specific requirements
Solution Approach 2:
The invention utilizes multi-directional transfer capabilities to efficiently cover large display areas. By transferring micro LEDs in perpendicular directions (first and second directions), the system can fill large substrates more rapidly than single-direction approaches, maintaining productivity despite increased area
Data Source
AI summary
A method of aligning micro light emitting elements includes supplying the plurality of micro light emitting elements on a substrate including a plurality of grooves having different shapes, the plurality of micro light emitting elements being configured to be inserted exclusively and respectively into the plurality of grooves; respectively inserting the plurality of micro light emitting elements into the plurality of grooves; and aligning the plurality of micro light emitting elements, wherein at least one groove of the plurality of grooves has a shape that is different from a shape of a respective micro light emitting element inserted into the at least one groove.