Micro LED Multi-Color Transfer on Temporary Substrates
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Solution Overview
Problem
The existing process of transferring Micro LEDs to array substrates in Micro LED display panels involves a large number of transfers, resulting in low transfer efficiency and yield due to the small size of Micro LEDs and the complexity of the transfer process.
Innovation Solution
A Micro LED transfer method that involves transferring Micro LEDs of multiple colors from growth substrates to temporary substrates and then simultaneously transferring them to array substrates, reducing the number of transfers required and improving alignment and pickup efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Micro LEDs are transferred multiple times from growth substrates to array substrates through conventional processes, then the transfer process can be completed, but the transfer efficiency and yield are low due to the large number of transfers required
Solution Approach 1:
The patent merges multiple transfer operations into a single transfer process by integrating Micro LEDs of different colors onto one temporary substrate. Instead of transferring each color separately through multiple steps, all Micro LEDs are transferred simultaneously in one operation, directly reducing the number of transfers and improving transfer efficiency.
Solution Approach 2:
The patent performs preliminary arrangement of Micro LEDs of different colors on a temporary substrate before the final transfer to the array substrate. This preliminary organization allows all Micro LEDs to be positioned and ready for a single consolidated transfer operation, eliminating the need for multiple sequential transfers.
2Manufacturing precision
If Micro LEDs of different colors are transferred separately through multiple processes, then each color can be precisely positioned, but the overall transfer yield decreases due to cumulative errors and losses
Solution Approach 1:
The patent combines the transfer of Micro LEDs of different colors into a single simultaneous transfer operation. This merging eliminates cumulative alignment errors that would occur in multiple sequential transfers and prevents yield losses from repeated handling, while maintaining precision through the unified transfer process.
3Quantity of substance
If the distance between adjacent Micro LEDs on the temporary substrate is smaller than on the array substrate, then more Micro LEDs can be accommodated on the temporary substrate, but the density increases making handling more difficult
Solution Approach 1:
The patent segments the Micro LED array into multiple temporary substrates, each containing a manageable number of Micro LEDs with smaller spacing. This segmentation allows high-density packaging while maintaining ease of operation by dividing the total quantity across multiple smaller, more manageable substrates that can be handled and transferred efficiently.
Data Source
AI summary
A Micro LED transfer method, a display panel, and a fabrication method of the display panel are provided. The Micro LED transfer method includes: transferring Micro LEDs of at least two colors from growth substrates thereof to a plurality of first temporary substrates, respectively, where a first temporary substrate includes Micro LEDs of the at least two colors; and transferring the Micro LEDs of the at least two colors located on a same first temporary substrate to at least one array substrate. A same array substrate includes Micro LEDs of the at least two colors, and the Micro LEDs of the at least two colors located on the same array substrate are simultaneously transferred. A distance between adjacent Micro LEDs of a same color on the first temporary substrate is smaller than a distance between adjacent Micro LEDs of the same color on the array substrate.