Micro LED Transfer Film Stretching for Precise Display Panel Layout
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Solution Overview
Problem
The fabrication of display panels using inorganic light-emitting elements requires precise arrangement of micro LEDs on a substrate, which is challenging due to the need for precise positioning and uniform spacing of these elements.
Innovation Solution
A method involving the formation of light-emitting elements on a base substrate, initial transfer to a first film, elongation of the first film using gas pressure to rearrange the elements, and subsequent transfer to a second film secured to a stage, where they are precisely positioned and bonded to a display substrate using a cell mask and laser irradiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light-emitting elements are directly transferred to the display substrate, then the transfer process is simple, but the positioning precision and uniform spacing are insufficient
Solution Approach 1:
The patent introduces a first film as an intermediary carrier for initial transfer and a second film as a final carrier for precise positioning. The first film receives light-emitting elements through initial transfer, then undergoes elongation to adjust spacing, and finally transfers elements to the second film which is positioned on the display substrate. This multi-stage intermediary transfer process resolves the contradiction by achieving high positioning precision through the second film's precise placement while managing complexity through systematic process division.
Solution Approach 2:
The patent performs preliminary actions including: (1) initial transfer of light-emitting elements to the first film before final positioning, (2) elongation of the first film to pre-adjust spacing between elements, and (3) preparation of the second film with precise positioning features. These preliminary actions enable the final transfer to achieve high positioning precision without requiring complex real-time adjustment mechanisms during the actual mounting process.
2Manufacturing precision
If the first film is elongated to increase distance between light-emitting elements, then uniform spacing is achieved, but the film deformation control becomes more difficult
Solution Approach 1:
The patent changes the physical parameters of the first film by applying controlled elongation force, causing the film to stretch and increase the distance between light-emitting elements. This parameter change (from relaxed to elongated state) achieves uniform spacing distribution. The process manages manufacturing difficulty through controlled application of force and subsequent relaxation, where the film's elastic properties enable predictable deformation and recovery.
Solution Approach 2:
The patent employs dynamic manipulation of the first film through elongation and relaxation cycles. The film transitions from a static state to a dynamically deformed state during elongation, then returns to a relaxed state after element transfer. This dynamic approach enables uniform spacing achievement through controlled deformation while maintaining manufacturing ease through reversible elastic behavior of the film material.
3Manufacturing precision
If multiple transfer stages are used, then positioning precision is improved, but the fabrication time increases
Solution Approach 1:
The patent segments the transfer process into distinct stages: initial transfer to the first film, elongation of the first film, transfer to the second film, and final positioning on the display substrate. Each segment performs a specific function that contributes to overall positioning precision. The segmentation enables parallel processing potential and systematic optimization of each stage, reducing total fabrication time compared to attempting single-step precise transfer.
Solution Approach 2:
The patent performs preliminary transfer to the first film and elongation before final positioning on the display substrate. This preliminary preparation of elements in controlled stages allows for efficient batch processing and reduces the complexity and time of the final critical positioning step, as elements are pre-organized and spaced correctly before being transferred to their final destinations.
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 allows for the uniform and precise arrangement of light-emitting elements on a display panel substrate, enhancing the fabrication efficiency and quality of the display panels.
Implementation Method 1
elongating the first film by pressurizing the first film with gas
Implementation Method 2
elongating the first film by pressurizing the first film with gas
Implementation Method 3
irradiating the portion of the second film with a laser
Implementation Method 4
irradiating the portion, the light-emitting elements rearranged and positioned in the portion of the second film may be bonded to the display substrate
Data Source
AI summary
A method of fabricating a display panel includes forming light-emitting elements on a base substrate, initially transferring the light-emitting elements to a first film, securing the first film on which the light-emitting elements are arranged, elongating the first film by pressurizing the first film with gas, and secondarily transferring the light-emitting elements, which are rearranged by elongating the first film, to a second film secured to a stage.