Micro LED Laser Transfer Apparatus for Defective Pixel Repair

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Solution Overview

Problem

The manufacturing process of micro LED displays is inefficient due to time-consuming repair processes for defective micro LEDs, as removing and replacing impaired LEDs on a substrate is labor-intensive and prone to defects.

Innovation Solution

A method and apparatus utilizing a laser transfer technique to identify and replace defective micro LEDs on a substrate by selecting a suitable replacement from a second substrate based on proximity and characteristic matching, allowing for sequential scanning and alignment to transfer the replacement LEDs to the defective positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual repair process is used to remove and replace defective micro LEDs, then repair capability is maintained, but manufacturing time and labor cost increase significantly

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidrepair process time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical repair operations with an automated laser-based transfer system. The laser transfer apparatus uses optical energy to precisely remove defective micro LEDs and transfer replacement LEDs to correct positions, eliminating manual labor and significantly reducing repair time while maintaining high precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables automated self-service repair by automatically identifying defective micro LEDs, selecting appropriate replacement LEDs from the same substrate, and transferring them to correct positions. This self-contained automated process eliminates the need for external manual intervention and accelerates the repair cycle.

Inventive Principle:

Principle #25Self-service

2Productivity

If repair process is automated to improve efficiency, then manufacturing speed increases, but system complexity increases

Engineering Contradiction:

Improverepair process speedVSAvoidtransfer apparatus complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The laser transfer apparatus performs multiple functions using a single integrated system: it identifies defective micro LEDs, selects replacement LEDs from the same substrate, removes defective LEDs, and transfers replacement LEDs to correct positions. This multi-functional approach achieves high automation while avoiding the need for separate complex systems for each operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses a transfer substrate as an intermediary carrier to hold multiple replacement micro LEDs. This intermediary structure simplifies the transfer process by allowing batch preparation of replacement LEDs and systematic transfer to multiple defect positions, reducing the complexity of direct one-to-one replacement operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If replacement micro LEDs are selected from same substrate based on proximity, then color consistency is improved, but selection complexity increases

Engineering Contradiction:

Improvecolor consistencyVSAvoidselection process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system applies local quality selection by choosing replacement micro LEDs from locations adjacent to defective positions on the same substrate. This ensures that replacement LEDs share similar local manufacturing conditions and material batches, guaranteeing color consistency and luminance uniformity without requiring complex global optimization algorithms.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent performs preliminary arrangement of multiple replacement micro LEDs on a transfer substrate before the actual transfer process. This preliminary action organizes replacement candidates in advance, allowing the system to efficiently select and transfer LEDs without complex real-time decision-making during the transfer operation itself.

Inventive Principle:

Principle #10Preliminary action

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 efficiency of the repair process by reducing the time and effort required for replacing defective micro LEDs, ensuring minimal disruption to the display's luminance and color consistency.

Implementation Method 1

transferred to the first substrate by using a laser transfer method

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11437541B2Transfer apparatus and method of manufacturing micro LED display using the same

Publication Date: 2022.09.06 SAMSUNG ELECTRONICS CO LTD

AI summary

A method of manufacturing a micro light emitting diode (LED) display and a transfer apparatus are provided. The method of manufacturing a micro LED display includes: identifying a repairing micro LED, from among a plurality of second micro LEDs, on a second substrate based on a first position of a defective micro LED, from among a plurality of first micro LEDs, on a first substrate; removing the defective micro LED from the first substrate; matching the first position on the first substrate from which the defective micro LED has been removed to a second position of the repairing micro LED on the second substrate; and transferring the repairing micro LED from the second position on the second substrate to the first position on the first substrate from which the defective micro LED has been removed, by using a laser transfer method.