Micro-LED Transfer Stamp Using UV Photochromism

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Solution Overview

Problem

The production yield of micro-LED display devices is low due to complications and low efficiency in the transfer process of thousands or tens of thousands of micro-LEDs from a wafer to an array substrate, resulting in decreased optical efficiency and durability.

Innovation Solution

A micro-LED display device with a substrate featuring a first insulating layer with varying hydrophilicity regions, where UV and visible-ray irradiation are used to enhance and decrease hydrophilicity on a stamp for efficient transfer of micro-LEDs, improving adhesion and separation processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a stamp is used to transfer thousands or tens of thousands micro-LEDs from a wafer to an array substrate, then the micro-LED display device can be manufactured, but the transfer process becomes very complicated and the yield is significantly low

Engineering Contradiction:
Improvetransfer yieldVSAvoidtransfer process complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by utilizing UV irradiation to alter the surface energy characteristics of the stamp material. This causes a reversible change in the hydrophilicity/hydrophobicity of the stamp surface, enabling controlled adhesion and release of micro-LEDs during the transfer process, thereby simplifying the transfer operation and improving yield.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent implements dynamics by making the stamp's surface properties dynamically changeable through UV irradiation. The stamp transitions between adhesive and non-adhesive states, allowing the transfer process to be controlled in two stages: first adhering micro-LEDs to the stamp, then releasing them onto the array substrate, thus reducing process complexity and improving transfer efficiency.

Inventive Principle:
Principle #15Dynamics

2Strength

If UV ray irradiation is used to increase hydrophilicity of the stamp for transferring micro-LEDs, then adhesion is improved, but the stamp requires subsequent treatment to decrease hydrophilicity for separation

Engineering Contradiction:
Improveadhesion strengthVSAvoidseparation process time
Core Design Contradiction:
StrengthVSLoss of time

Solution Approach 1:

The patent applies periodic action by using sequential UV and visible-ray irradiation to cyclically change the stamp's surface properties. UV irradiation creates a high-adhesion state for picking up micro-LEDs, while subsequent visible-ray irradiation creates a low-adhesion state for release, enabling efficient periodic transfer cycles without manual intervention.

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent replaces mechanical separation processes with optical control. Instead of using mechanical force to separate micro-LEDs from the stamp, the patent uses visible-ray irradiation to optically induce hydrophobicity changes on the stamp surface, causing automatic release of micro-LEDs and eliminating complex mechanical separation mechanisms.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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

The method enhances the transfer efficiency and yield of micro-LEDs, reducing production costs and improving the optical efficiency and durability of the micro-LED display device.

Implementation Method 1

irradiating a UV ray on the stamp to increase a hydrophilicity of the stamp

Methodology Applied
Scientific EffectPhotochromism: Photochromism

Implementation Method 2

irradiating a visible-ray to the stamp to decrease the hydrophilicity of the stamp

Methodology Applied
Scientific EffectPhotochromism: Photochromism

Data Source

PatentUS10741728B2Micro-LED display device and method of fabricating the same
Publication Date: 2020.08.11 LG DISPLAY CO LTD
  • US10741728B2 patent drawing
  • US10741728B2 patent drawing
  • US10741728B2 patent drawing

AI summary

A micro-LED display device includes a substrate; a first insulating layer on the substrate and including a first region and a second region; and a micro-LED in the first region, wherein the first region has a first hydrophilicity, and the second region has a second hydrophilicity that is less than the first hydrophilicity.