Micro-LED Array Circular Groove Alignment for Faster Transfer
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Solution Overview
Problem
The existing methods for transferring micro-LEDs onto a driving circuit substrate are inefficient, particularly as the size of micro-LEDs decreases and the display area increases, leading to increased time and costs due to the need for multiple transfer processes and alignment with grooves of varying shapes.
Innovation Solution
A micro-LED array structure is designed with circular grooves on a first substrate and electrodes on both micro-LEDs and a driving circuit substrate, allowing for efficient alignment and bonding through wet or dry alignment methods, including the use of an absorber to facilitate alignment with liquid absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional pick and place method is used to transfer micro-LEDs, then individual micro-LEDs can be transferred, but productivity declines as micro-LED size decreases and display area increases
Solution Approach 1:
The invention segments the transfer process by creating an array structure where multiple micro-LEDs are transferred simultaneously in groups rather than individually. The driving circuit substrate is divided into multiple regions with corresponding electrode structures, allowing batch transfer operations that significantly improve productivity while reducing total transfer time.
Solution Approach 2:
The invention merges multiple transfer operations into a single process by aligning arrays of micro-LEDs with arrays of electrode structures on the driving circuit substrate. This combining approach allows simultaneous transfer of multiple micro-LEDs, directly addressing the productivity decline issue with traditional sequential pick and place methods.
2Adaptability or versatility
If multiple transfer processes are used to transfer micro-LEDs emitting multiple colors, then all required colors can be achieved, but much time is required for transferring operation
Solution Approach 1:
The invention applies preliminary action by pre-organizing micro-LEDs of different colors into arrays on temporary substrates before transfer. The electrode structures on the driving circuit substrate are also pre-configured with corresponding color assignments. This preliminary arrangement allows all color transfers to occur in a single synchronized operation rather than requiring sequential multi-color transfer processes.
Solution Approach 2:
The electrode structure design provides universality by creating a single transfer process that can handle multiple colors simultaneously. The driving circuit substrate with its array of electrode structures serves multiple functions: it receives all color micro-LEDs in one operation, maintains proper alignment for different colors, and enables subsequent driving operations for all colors through the unified electrode array.
3Manufacturing precision
If micro-LEDs are aligned with grooves of varying shapes, then alignment can be achieved, but alignment time increases and complexity increases
Solution Approach 1:
The invention applies homogeneity by standardizing the groove structures on the driving circuit substrate into uniform circular shapes rather than varying shapes. This uniformity simplifies the alignment process significantly, as all micro-LED arrays can be aligned using the same circular reference pattern. The homogeneous circular groove design maintains manufacturing precision while dramatically reducing alignment time and operational complexity.
4Area of stationary object
If area of driving circuit substrate is increased to accommodate larger display, then larger display can be formed, but number of transfer processes increases
Solution Approach 1:
The invention transitions from one-dimensional sequential transfer to two-dimensional parallel transfer by organizing micro-LEDs and electrode structures into arrays. This dimensional change allows multiple transfer operations to occur simultaneously across the expanded substrate area, maintaining high productivity even as display size increases. The array-based approach enables the system to scale to larger areas without proportionally increasing transfer process count.
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 structure enables faster and more cost-effective transfer of micro-LEDs onto a driving circuit substrate, reducing alignment time and material waste, while maintaining electrical connectivity.
Implementation Method 1
including the use of an absorber to facilitate alignment with liquid absorption
Data Source
AI summary
A method of manufacturing a micro-light-emitting diode (LED) array includes: providing a first substrate including a plurality of circular grooves formed on a first surface thereof; supplying a plurality of micro-LEDs onto the first surface of the first substrate; and aligning the plurality of micro-LEDs with the plurality of circular grooves, wherein at least two electrodes are formed on a second surface of each of the plurality of micro-LEDs to be apart from each other, and the at least two electrodes include a first electrode formed to be relatively close to a center of the second surface and at least one second electrode formed at an edge of the second surface.