Micro LED Transfer Assembly for High-Resolution Color Displays
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Solution Overview
Problem
The challenge lies in efficiently mounting and transferring large numbers of small micro LEDs onto a display panel substrate, as their small size complicates handling and mounting, leading to difficulties in creating high-resolution displays with precise color representation.
Innovation Solution
A method involving the formation of light emitting devices on a growth substrate, followed by a transfer process using temporary substrates and mask layers to securely attach and separate the micro LEDs onto a display panel substrate, ensuring precise alignment and connection for efficient display manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro LEDs are made smaller to increase pixel density, then display resolution is improved, but handling and mounting difficulty increases
Solution Approach 1:
The patent introduces temporary substrates as intermediary carriers that hold multiple micro LEDs during fabrication and transfer processes. These temporary substrates act as mediators between the micro LED fabrication process and the final display assembly, enabling easy handling and precise placement of extremely small micro LEDs without direct manual manipulation.
Solution Approach 2:
The patent divides the micro LED fabrication and assembly process into separate stages using multiple temporary substrates. Each temporary substrate holds a specific array of micro LEDs, allowing independent processing, testing, and transfer. This segmentation enables precise control and handling of small micro LEDs through automated processes rather than direct manipulation.
2Manufacturing precision
If a large number of micro LEDs are arranged on one substrate, then display quality is improved, but the complexity of mounting increases
Solution Approach 1:
The patent segments the large array of micro LEDs into multiple smaller groups, with each group mounted on a separate temporary substrate. This division reduces the complexity of handling and mounting by breaking down the large-scale operation into manageable units that can be processed independently and then integrated into the final display.
Solution Approach 2:
Temporary substrates serve as intermediary carriers that simplify the mounting process. Instead of directly mounting hundreds or thousands of micro LEDs onto the final display substrate, the temporary substrates provide organized arrays that can be systematically transferred, reducing overall mounting complexity while maintaining display quality.
3Ease of manufacture
If micro LEDs are directly mounted on display panel, then manufacturing process is simplified, but alignment precision and connection reliability deteriorate
Solution Approach 1:
The patent performs preliminary organization and positioning of micro LEDs on temporary substrates before final transfer to the display panel. This preliminary action includes forming precise patterns, establishing connections, and organizing arrays on the temporary substrates, which ensures accurate alignment and reliable connections are achieved before the critical final mounting step.
Solution Approach 2:
Temporary substrates act as intermediary platforms that enable precise alignment and reliable connections to be established in a controlled environment before final transfer. The intermediaries provide stable bases for forming precise electrical and mechanical connections, which are then maintained during the transfer process to the final display panel.
Data Source
AI summary
A displaying apparatus includes a pixel unit. The pixel unit includes at least one pixel having a light emitting device and a light conversion layer for converting a first wavelength of light of the light emitting device into a second wavelength of light different from the first wavelength; and an insulation layer covers side surfaces of the light emitting device and the light conversion layer.