Flexible Barrier Rib Transfer for Micro LED Alignment
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Solution Overview
Problem
Existing methods for manufacturing micro LEDs, such as laser lift off and pick and place, result in reduced productivity when micro LEDs become smaller and displays become larger in size.
Innovation Solution
A display transfer structure comprising a base layer with a flexible barrier rib having holes for micro LEDs, where each micro LED is aligned with its electrode facing outward, and a method of manufacturing this structure using a flexible barrier rib with a polymer and metal layer to facilitate large-area transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser lift off or pick and place methods are used to transfer micro LEDs, then micro LEDs can be transferred, but productivity is reduced when micro LEDs become smaller and displays become larger in size
Solution Approach 1:
The invention segments the transfer process into two distinct stages: first, en-masse transfer of multiple micro LEDs from the LED substrate to the transfer substrate; second, precise positioning and transfer of micro LEDs from the transfer substrate to the final display substrate. This segmentation enables high-volume transfer in the first stage, significantly improving productivity for large displays while maintaining precision in the second stage.
Solution Approach 2:
The invention introduces a transfer substrate as an intermediary carrier between the LED substrate and the final display substrate. This intermediary enables the decoupling of the transfer process, allowing en-masse transfer followed by precise positioning, thereby resolving the contradiction between productivity and precision for large-scale displays.
2Manufacturing precision
If micro LEDs become smaller to increase display resolution, then display quality improves, but transfer productivity decreases
Solution Approach 1:
By segmenting the transfer process into en-masse transfer and precise positioning stages, the invention achieves high transfer productivity in the first stage regardless of micro LED size, then ensures high precision positioning in the second stage. This resolves the contradiction between small micro LED size for high resolution and transfer productivity.
Solution Approach 2:
The transfer substrate structure, including the recesses and elastic layer, is designed to automatically guide and position micro LEDs during transfer through self-aligning mechanisms, reducing the need for complex external positioning systems and maintaining high productivity even as micro LED dimensions decrease.
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 efficient alignment and transfer of micro LEDs onto larger substrates, enhancing productivity and flexibility in display manufacturing processes.
Implementation Method 1
Each of the plurality of holes may have a cross-section larger than a cross-section of the respective micro LED
Implementation Method 2
An upper surface of the flexible barrier rib may be more hydrophobic than a surface of the base layer exposed by the plurality of holes
Implementation Method 3
The polymer material may include a photosensitive material
Data Source
AI summary
A display transfer structure includes a base layer, a flexible barrier rib positioned on the base layer and having a plurality of holes therein, and a plurality of micro light emitting diodes (LEDs) positioned respectively in the plurality of holes. A method of manufacturing the display transfer structure includes forming a flexible barrier rib having holes on a base layer, supplying liquid to the holes, supplying micro LEDs to the liquid, and scanning the flexible barrier rib with an absorber capable of absorbing the liquid to align each of the micro LEDs in a respective hole such that electrodes of the micro LEDs face an outside of the holes.