Micro LED Transfer Head Folding for Protective Film Integrity
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Solution Overview
Problem
The existing methods for manufacturing display panels using inorganic light-emitting diodes face challenges in accurately and efficiently transferring micro LEDs onto substrates without damaging the protective films, leading to unwanted removal or pushing of these films during the folding process.
Innovation Solution
A transfer device and method that includes a transferer with a tacky or adhesive stamp layer, a base layer, and a protective film with an incision groove, utilizing an inverter to invert and fold the transferer, and a transfer head to adsorb and lift the light-emitting element, ensuring the protective film is properly peeled off and the element is securely transferred onto a circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the protective film is removed before folding, then the folding process becomes easier and more accurate, but the protective film may be unwantedly removed or pushed during folding
Solution Approach 1:
The protective film is intentionally removed from the folding portion before the folding operation begins. This preliminary action prepares the folding portion for accurate folding by eliminating the protective film that would otherwise interfere with the folding process, while the transfer head maintains adsorption on the base layer to prevent unwanted film removal during subsequent operations.
Solution Approach 2:
The transfer head serves as an intermediary device that selectively manages the protective film. It adsorbs to the base layer and controls the folding process, enabling the folding portion to be folded accurately while preventing the transfer unit from being affected by the protective film removal, thus mediating between the need for film removal and film protection.
2Reliability
If the protective film remains attached during folding, then the transfer unit is protected, but the folding accuracy decreases due to unwanted removal or pushing of the film
Solution Approach 1:
The transfer member is divided into two distinct portions: the transfer unit and the folding portion. The protective film is selectively removed only from the folding portion while remaining on the transfer unit. This segmentation allows the folding portion to be folded with high accuracy without film interference, while the transfer unit remains protected by its protective film throughout the process.
Solution Approach 2:
Different regions of the transfer member have different protective film states: the folding portion has the protective film removed to enable accurate folding, while the transfer unit retains the protective film for protection. This local differentiation of quality (protected vs. unprotected regions) allows simultaneous achievement of folding accuracy and transfer unit protection.
3Reliability
If the transferer is folded without removing the protective film, then the protective film remains intact, but the folding process becomes complex and time-consuming
Solution Approach 1:
The protective film is removed from the folding portion as a preliminary step before folding begins. This preliminary removal simplifies the subsequent folding operation, making it faster and more straightforward. The transfer head maintains adsorption to ensure the protective film is not unintentionally removed from the transfer unit during this process, balancing film integrity with manufacturing efficiency.
4Manufacturing precision
If the protective film is removed selectively from the folding portion, then folding accuracy improves, but the process complexity increases
Solution Approach 1:
The transfer head acts as an intermediary that simplifies the selective protective film removal process. By adsorbing to the base layer, it provides controlled access to the folding portion, enabling selective film removal through a unified adsorption-based mechanism rather than requiring separate complex removal systems for different regions.
Solution Approach 2:
The transfer head performs multiple functions: it adsorbs to the base layer, enables selective protective film removal from the folding portion, maintains protection of the transfer unit, and controls the folding process. This multi-functionality reduces overall process complexity by consolidating multiple operations into a single versatile device.
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 reduces the likelihood of protective film damage during folding and improves the accuracy of light-emitting element transfer, enhancing production efficiency by minimizing rejects and ensuring proper adhesion to the circuit board.
Implementation Method 1
a stamp layer having a tacky or adhesive surface
Implementation Method 2
a support chuck configured to adsorb the protective film overlapping the transferring portion, and a side chuck configured to adsorb the protective film overlapping the folding portion
Data Source
AI summary
A transfer device of a light-emitting element, the transfer device including: a transferer including a transferring portion, a folding portion at an edge, a stamp layer having a tacky or adhesive surface, and a base layer above one surface of the stamp layer; a protective film above an other surface of the stamp layer, and defining an incision groove with the transferring portion at a center thereof on a plane; an inverter for inverting up, down, left, and right sides of the transferer, and including a support chuck configured to adsorb the protective film overlapping the transferring portion, and a side chuck configured to adsorb the protective film overlapping the folding portion; a transfer head having a head chuck configured to be adsorbed to the base layer, and movable up, down, left, and right; and a folder including a detachable first clamp.