Micro LED Mass Transfer via Buoyant Suspension and Adhesive Roller
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Solution Overview
Problem
Transferring a large number of micro LEDs to a display substrate with high reliability during manufacturing is challenging due to their small size.
Innovation Solution
A mass transfer system and method involving a chamber with a suspension liquid, a positioning substrate with holes, and a transfer roller to efficiently transfer micro LEDs from a suspension to an array substrate, utilizing buoyancy and adhesive or magnetic mechanisms to ensure precise placement and adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional transfer methods are used for micro LEDs, then the transfer process is simple, but the transfer reliability is low due to small size
Solution Approach 1:
A liquid suspension medium is introduced as an intermediary to hold and transport micro LEDs. The micro LEDs are suspended in liquid droplets, which are then transferred using a multi-layer structure consisting of a pickup layer, transfer layer, and release layer. This intermediary liquid phase enables reliable transfer of tiny micro LEDs that cannot be handled by direct mechanical methods.
Solution Approach 2:
The micro LEDs are extracted from the liquid suspension and transferred to a target substrate through a controlled process. The pickup layer absorbs liquid droplets containing micro LEDs, separates them from the bulk suspension, and enables precise placement on the display substrate.
2Productivity
If manual or traditional automated transfer methods are used, then equipment complexity is low, but productivity is insufficient for mass transfer
Solution Approach 1:
Multiple functions are merged into a single integrated transfer head structure. The pickup layer, transfer layer, and release layer are combined in one component that can simultaneously handle multiple liquid droplets containing micro LEDs. This enables mass transfer operations while maintaining a relatively compact device structure.
Solution Approach 2:
The transfer system is designed with universal applicability for transferring large numbers of micro LEDs. The multi-layer structure can be reused for multiple transfer operations, and the system can handle various configurations of micro LEDs in liquid suspension, making it suitable for mass production scenarios.
3Manufacturing precision
If micro LEDs are transferred individually, then placement precision is achievable, but transfer time and cost increase
Solution Approach 1:
Multiple micro LEDs are combined into liquid droplets that are transferred simultaneously. Each droplet contains one or more micro LEDs, and the pickup layer can absorb and transfer multiple droplets in parallel. This maintains placement precision while achieving mass transfer in a single operation cycle.
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 reliable transfer of tens or hundreds of thousands of micro LEDs with high efficiency and low cost, optimizing their arrangement and presentation on the substrate for improved display resolution and contrast.
Implementation Method 1
a suspending liquid is used to float a plurality of micro LEDs on a surface of the suspending liquid
Implementation Method 2
rolling the transfer roller over and along the positioning substrate away from the suspending liquid to gain adherence of the micro LEDs
Data Source
AI summary
A method and system for rapid and efficient mass transfer of a quantity of micro LEDs from storage onto a display substrate provides a micro LED which includes an electrode part, a luminous part, and a suspending part. The electrode part includes at least one electrode. The luminous part emits a certain color of light. The matter density of the suspending part is reduced to be less than that of a liquid holding the quantity of micro LEDs in suspension, and also less than the matter density of the other two parts of the micro LED. Even before illumination, the suspending part has the same color as the color of light to be emitted by that micro LED. A mass transfer system and a mass transfer method are disclosed.