Asymmetric Holding Structures for Micro LED Transfer Yield
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Solution Overview
Problem
The existing methods for transferring micro light-emitting diodes (LEDs) between substrates often face challenges due to the positioning of holding structures, which can affect the yield and stability of the transfer process, leading to uneven forces during handling and placement.
Innovation Solution
A micro device structure featuring holding structures on the top surface of micro devices that extend to the substrate, with varying distances between holding structures on adjacent rows, allowing for improved positioning and force distribution during transportation and transfer, thereby enhancing the yield and stability of the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If holding structures are disposed on micro LEDs to facilitate pickup and transfer, then ease of operation is improved, but positions of holding structures may influence transportation and transfer yield
Solution Approach 1:
The patent applies asymmetry by configuring holding structures at different positions on micro LEDs in different rows. Specifically, holding structures in first and third rows are positioned at different locations compared to holding structures in second and fourth rows, creating an asymmetric pattern that optimizes both pickup ease and transfer yield simultaneously
2Stability of the object's composition
If holding structures are used to secure micro LEDs during transfer, then stability is improved, but uneven forces during handling occur
Solution Approach 1:
The asymmetric positioning of holding structures across different rows creates a more uniform force distribution pattern during pickup and transfer operations. By alternating holding structure positions in adjacent rows, the design balances the mechanical stresses and forces applied to micro LEDs, preventing concentration of force at single points while maintaining stable transfer
Data Source
AI summary
A structure with micro device includes a substrate, a plurality of micro devices, and a plurality of holding structures. The micro devices are disposed on the substrate and arranged in multiple rows. Each of the micro devices has a top surface. The holding structures are respectively disposed on the top surface of each of the micro devices and extend to the substrate. Distances between the holding structure on the micro devices on any one of the rows and the holding structures on the micro devices on two adjacent rows are different.