Micro LED Display Panel Alignment Precision via Patterning
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Solution Overview
Problem
The existing bonding methods for micro light emitting diodes (micro LEDs) face challenges due to low alignment precision, resulting in a high defect rate when transferring and bonding transverse micro LEDs onto substrates, particularly due to the small size of the solder pads and alignment tolerance issues.
Innovation Solution
A display panel design that includes driving electrodes and micro LEDs with exposed electrodes on the same side of the substrate, allowing for higher precision in forming driving wires using patterning processes, along with a buffer structure and connection structure to enhance alignment and fixation, reducing the need for precise bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional bonding methods are used to bond micro LED electrodes to driving electrodes, then the bonding process can be completed, but the alignment precision is low resulting in high defect rate
Solution Approach 1:
The micro LED is transferred to the substrate with its electrodes exposed on the same side as the driving electrodes, in advance of the wire formation step. This preliminary arrangement of electrodes enables subsequent high-precision patterning processes to create driving wires that accurately connect corresponding electrodes, achieving alignment precision of 1-2 micrometers and significantly reducing bonding defects
Solution Approach 2:
The patent replaces the traditional mechanical bonding process with a patterning-based wire formation process. Instead of using bonding tools to physically connect electrodes, the invention uses photolithography or other patterning methods to deposit conductive material that forms driving wires, achieving much higher alignment precision (1-2 micrometers) compared to conventional bonding methods
2Manufacturing precision
If transverse micro LED structure is used with electrodes on the same side, then driving wires can be formed with higher precision using patterning processes, but additional process steps are required
Solution Approach 1:
The patent merges the micro LED transfer step with the electrode exposure arrangement, so that when the micro LED is transferred to the substrate, its electrodes are already positioned on the same side as the driving electrodes. This merging of functions eliminates the need for separate electrode positioning steps and simplifies the overall process while enabling high-precision driving wire formation through patterning
Data Source
AI summary
The present disclosure provides a display panel and a manufacturing method thereof, a display device. The display panel includes: a substrate; a plurality of driving electrodes and a micro light emitting diode located on a surface of the substrate, wherein respective electrodes of the micro light emitting diode are located at a side of the micro light emitting diode facing away from the substrate; and a plurality of driving wires respectively electrically coupling the respective electrodes of the micro light emitting diode to the plurality of driving electrodes.