Micro LED Alignment via Asymmetric Transfer Mold Geometry
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Solution Overview
Problem
Current methods for manufacturing high-resolution displays using micro LEDs face challenges in efficiently aligning micro LEDs during the transfer process, leading to misalignment and inefficiencies in the production of micro LED displays.
Innovation Solution
A method involving a transfer substrate with a mold having openings that accommodate the first surface of micro LEDs but not the second surface, allowing for precise alignment of micro LEDs in one direction by inserting them into the openings, ensuring the first surface is positioned correctly, and removing misaligned LEDs until all are properly aligned.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional transfer processes are used to arrange micro LEDs, then micro LEDs can be placed on substrates, but misalignment occurs and manufacturing efficiency is reduced
Solution Approach 1:
The patent utilizes the asymmetric geometry of micro LEDs, where the first surface has a smaller maximum width than the second surface. The transfer mold openings are designed to accommodate only the smaller first surface, creating a geometric constraint that enables automatic orientation and alignment during the transfer process, thereby eliminating misalignment issues while maintaining high manufacturing efficiency
Solution Approach 2:
The transfer mold with specifically designed openings acts as an intermediary tool that facilitates precise alignment. The openings serve as geometric guides that receive and orient the micro LEDs by their unique first surface geometry, enabling accurate placement without requiring complex alignment mechanisms or reducing production speed
2Ease of manufacture
If micro LEDs are transferred without directional alignment, then the transfer process is simpler, but misalignment occurs between micro LEDs and substrate positions
Solution Approach 1:
The asymmetric dimensions of the micro LED first surface relative to the transfer mold opening create a self-aligning mechanism. The smaller first surface fits into the opening in only one correct orientation, automatically ensuring proper alignment during transfer without requiring complex alignment procedures, thus maintaining both simplicity and precision
Solution Approach 2:
The micro LED's own geometric asymmetry serves the alignment function. The unique first surface geometry inherently provides the alignment information needed during transfer, eliminating the need for external alignment markers or complex positioning systems, thereby keeping the process simple while achieving high precision
Data Source
AI summary
A method of aligning micro LEDs and a method of manufacturing a micro LED display using the same are provided. The method of aligning micro LEDs includes providing micro LEDs, each having a first surface that has a first maximum width and a second surface opposite to the first surface and has a second maximum width that is greater than the first maximum width, providing a transfer substrate including a transfer mold that has an array of openings, each of the openings being configured to accommodate the first surface of a corresponding micro LED and not accommodate the second surface of the corresponding micro LED and aligning the micro LEDs in one direction in the openings of the transfer mold by inserting the micro LEDs into the openings of the transfer mold so that the first surface of each of the micro LEDs is positioned within a corresponding opening.