Micro-LED Inkjet Transfer With Multi-Directional Emission Control
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Solution Overview
Problem
The existing methods for transferring micro LEDs in LED displays face inefficiencies and inaccuracies, particularly in large-region pixel array panels, where precise and rapid transfer of micro LEDs emitting different colors to sub-pixel regions is challenging, leading to issues with correct mounting and light emission.
Innovation Solution
The method involves using an inkjet technique to transfer micro LEDs with an active layer capable of emitting light in multiple directions, dividing sub-pixel regions into groups, and employing multiple inkjet heads to simultaneously or sequentially transfer red, green, and blue micro LEDs to each sub-pixel region, with a core-shell structure and light conversion materials to ensure accurate placement and light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional transfer methods are used for micro LEDs in large-region pixel array panels, then the transfer process can be completed, but the transfer efficiency is low and accuracy is poor
Solution Approach 1:
The pixel array panel is divided into multiple regions, and micro LEDs are transferred to different regions simultaneously using multiple inkjet heads. This segmentation approach increases overall transfer efficiency while maintaining precision in each region through dedicated inkjet head control.
Solution Approach 2:
Multiple inkjet heads are combined to perform simultaneous transfer operations across different regions of the pixel array panel. This merging of transfer operations parallelizes the process, significantly improving productivity without compromising accuracy through coordinated control of all inkjet heads.
2Quantity of substance
If micro LED size is reduced to increase pixel density, then more pixels can be accommodated, but light emission efficiency decreases
Solution Approach 1:
The active layer structure is modified with a core-shell configuration where the shell material has optimized optical properties. This parameter change in the material composition and structure compensates for the reduced size effects, maintaining light emission efficiency while enabling higher pixel density through smaller micro LED dimensions.
3Speed
If multiple inkjet heads are used to transfer different colored micro LEDs simultaneously, then transfer speed increases, but system complexity increases
Solution Approach 1:
Multiple inkjet heads are designed with identical or similar structures, each capable of transferring different colored micro LEDs. This universality allows the system to achieve high-speed parallel transfer while managing complexity through standardized components and centralized control architecture that treats each inkjet head as a repeatable unit.
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 approach significantly enhances the transfer efficiency and accuracy of micro LEDs to large-area pixel arrays, ensuring correct mounting and maintaining light emission efficiency, even with reduced LED sizes, thereby improving the overall performance of LED displays.
Implementation Method 1
transferring the at least one micro LED by spraying using an inkjet method
Data Source
AI summary
A method of transferring a micro light emitting diode (LED) to a pixel array panel includes transferring the micro LED by spraying using an inkjet method, wherein the micro LED includes an active layer including a first portion emitting light in a first direction and a second portion emitting the light in a second direction different from the first direction.