Micro LED Mass Transfer via Electromagnetic Attraction
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Solution Overview
Problem
Current technologies face challenges in efficiently and cost-effectively classifying and transferring miniaturized light emitting diodes (LEDs) by color during mass transfer processes due to their small size, making it difficult to integrate them into display devices.
Innovation Solution
A method involving a substrate with a basal layer, insulation layer, and electromagnetic generator, where grooves on the insulation layer correspond to metal contacts, allowing micro components to be attracted and electrically contacted by electromagnetic force, facilitating precise placement and transfer of micro LEDs onto a receiving substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If light emitting diodes are miniaturized to micron size, then compact size and energy efficiency are improved, but classification and transfer during mass transfer process becomes difficult and costly
Solution Approach 1:
The patent replaces traditional mechanical classification and transfer methods with electromagnetic force-based manipulation. By applying electromagnetic forces, micro components are precisely positioned and transferred without requiring complex mechanical handling systems, thereby reducing manufacturing complexity and costs while maintaining miniaturization benefits
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary between the transfer mechanism and the micro components. This intermediary enables non-contact manipulation and precise positioning of miniaturized LEDs during mass transfer, solving the handling difficulties associated with micron-scale components
2Productivity
If mass transfer process is used for multiple colors, then productivity is improved, but classification accuracy deteriorates due to small size
Solution Approach 1:
The patent replaces mechanical classification systems with electromagnetic field-based sorting. Different micro components respond differently to electromagnetic fields based on their properties, enabling automatic color classification during high-speed mass transfer without compromising accuracy despite the small component size
Solution Approach 2:
The patent utilizes changes in electromagnetic field parameters (such as frequency, intensity, or polarity) to differentiate and classify micro components by color during mass transfer. By dynamically adjusting these parameters, the system maintains high classification accuracy while achieving high productivity
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
This method enhances the efficiency and accuracy of transferring micro LEDs onto a substrate, enabling high transfer rates and integration into various display sizes, from micro to large area displays, while maintaining image quality.
Implementation Method 1
At least one electromagnetic force is provided, and a direction of the electromagnetic force is from the basal layer toward the insulation layer. The electrode is attracted to the corresponding groove by the electromagnetic force
Data Source
AI summary
A method of manufacturing display device is disclosed. A substrate includes a basal layer and metal contacts on the top surface. An insulation layer is disposed on the top surface and includes a first mounting surface and a bottom surface. Multiple grooves are formed on the insulation layer and each extends from the first mounting surface to the bottom surface. The grooves respectively correspond to the metal contacts and expose respective metal contacts. An electromagnetic force is provided with a direction from the basal layer toward the insulation layer. A droplet containing multiple micro components is provided on the first mounting surface. A configuration of an electrode of the micro component corresponds to a configuration of one of the grooves. The electrode is attracted to the corresponding groove by the electromagnetic force so as to electrically contact the metal contact.