Micro LED Transfer Array with Alignment Mask
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Solution Overview
Problem
Conventional micro LED transfer methods suffer from high misalignment frequencies between micro LEDs and bonding contacts on the target substrate, leading to defects in display panels due to the complexity of accurately placing thousands to millions of micro LEDs during the pick-and-place transfer process.
Innovation Solution
A micro LED transferring apparatus comprising a transfer array with multiple transfer heads and an array mask featuring alignment holes, where the transfer heads and micro LEDs are aligned using electrostatic or magnetic forces to ensure precise positioning, allowing for accurate placement of micro LEDs onto the target substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pick-and-place transfer methods are used for micro LEDs, then the transfer process can be completed, but high misalignment frequencies occur between micro LEDs and bonding contacts leading to defects
Solution Approach 1:
The patent introduces an array mask as an intermediary component with alignment holes that guides the transfer heads and micro LEDs to the correct positions on the target substrate. This mediator structure enables precise alignment without requiring complex control systems, thereby improving manufacturing precision and reducing defects caused by misalignment between micro LEDs and bonding contacts.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a simpler structure-based alignment mechanism. Instead of relying on precision mechanical positioning systems, the invention uses the geometric structure of alignment holes in the array mask to guide and constrain the positions of transfer heads and micro LEDs, achieving high alignment accuracy through structural design rather than mechanical control.
2Productivity
If the number of micro LEDs to be transferred increases to thousands or millions, then the display panel complexity increases, but the alignment difficulty and defect rate increase proportionally
Solution Approach 1:
The patent divides the transfer process into multiple independent transfer heads operating in parallel, each responsible for transferring micro LEDs through alignment holes in the array mask. This segmentation allows simultaneous transfer of thousands or millions of micro LEDs while maintaining alignment accuracy through the structured guidance of the array mask, enabling high productivity without sacrificing precision.
Solution Approach 2:
The array mask serves multiple functions simultaneously: it provides alignment guidance for transfer heads, defines the position of bonding contacts on the target substrate, and enables parallel transfer operations for multiple micro LEDs. This multi-functionality allows the system to handle large quantities of micro LEDs while maintaining consistent alignment accuracy across all transfer operations.
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 apparatus significantly reduces misalignment errors, enhancing the accuracy and reliability of the micro LED transfer process, thereby improving the quality and reducing defects in micro LED display panels.
Implementation Method 1
the controller is configured to apply a first voltage to the array of the plurality of transfer heads and apply a second voltage to the array mask at least in regions surrounding the array of the plurality of alignment holes
Implementation Method 2
the alignment mechanism comprises magnetic portions respectively in regions surrounding the array of the plurality of alignment holes and exposed magnetic portions of the array of the plurality of transfer heads
Implementation Method 3
the controller is configured to apply a magnetic field to the array of the plurality of transfer heads so that the exposed magnetic portions of the array of the plurality of transfer heads have a same magnetic polarity as the magnetic portions respectively in regions surrounding the array of the plurality of alignment holes
Data Source
AI summary
A micro light emitting diode (micro LED) transferring apparatus is provided. The micro LED transferring apparatus includes a transfer array including an array of a plurality of transfer heads; and an array mask having an array of a plurality of alignment holes. A respective one of the plurality of alignment holes has a size allowing a respective one of the plurality of transfer heads and a micro LED attached to the respective one of the plurality of transfer heads to pass through.