Micro LED Transfer Mask Layout for Precise Laser Alignment
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Solution Overview
Problem
The existing laser transfer method for micro LEDs suffers from accuracy issues due to non-uniform laser beam focus, leading to increased substrate replacement and manufacturing costs, as well as reduced efficiency in packing density of micro LEDs on the target substrate.
Innovation Solution
A display module and manufacturing method utilizing a mask with openings corresponding to the size and position of each micro LED on the transfer substrate, allowing for precise laser beam targeting and improved alignment, thereby minimizing the interval between micro LEDs and enhancing transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a laser beam is used to transfer micro LEDs from a relay substrate to a target substrate, then transfer speed is improved, but accuracy of laser beam focus deteriorates causing non-uniform transfer precision
Solution Approach 1:
A screen layer is introduced as an intermediary component between the laser beam and the relay substrate. This screen layer has light-transmitting portions positioned at each micro LED location, allowing the laser beam to selectively pass through and affect only the intended micro LED while blocking adjacent areas. This mediator enables high-speed laser transfer while maintaining precise spatial control and uniform focus accuracy across all micro LED positions.
2Manufacturing precision
If the size of the laser beam is increased to improve focus accuracy, then manufacturing precision is improved, but the interval between micro LEDs must be increased reducing packing density
Solution Approach 1:
The screen layer acts as a spatial filter that allows the use of larger laser beams without affecting adjacent micro LEDs. The light-transmitting portions of the screen layer are positioned to correspond exactly with each micro LED location, permitting increased laser beam size for better focus accuracy while the screen layer blocks the beam from affecting neighboring micro LEDs, thus maintaining high packing density.
3Manufacturing precision
If micro LEDs are arranged at wide intervals to avoid laser beam interference, then manufacturing precision is improved, but the area utilization of the relay substrate is reduced
Solution Approach 1:
The screen layer serves as a mediator that enables close spacing of micro LEDs on the relay substrate. By positioning light-transmitting portions at each micro LED location, the screen layer ensures that laser beams affect only the intended micro LED even when micro LEDs are densely packed, thus maximizing area utilization while maintaining transfer accuracy.
4Reliability
If the number of substrate replacements is increased to achieve complete transfer, then transfer completeness is improved, but manufacturing time and cost increase
Solution Approach 1:
The screen layer enables complete and accurate transfer of all micro LEDs from the relay substrate to the target substrate in a single laser processing operation. The light-transmitting portions ensure that every micro LED location receives precise laser energy, achieving complete transfer without requiring multiple substrate replacements, thus reducing manufacturing time and cost while maintaining transfer completeness.
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 allows for a higher packing density of micro LEDs on the target substrate, reducing the number of substrate replacements and manufacturing time, while maintaining high accuracy and efficiency in the transfer process.
Implementation Method 1
a plurality of micro light emitting diodes (LEDs) disposed on the TFT layer. The plurality of micro LEDs are transferred from a transfer substrate to the TFT layer by a laser beam radiated to the transfer substrate through openings of a mask
Data Source
AI summary
A display module is provided. The display module includes: a substrate; a thin film transistor (TFT) layer formed on one surface of the substrate; and a plurality of micro LEDs disposed on the TFT layer. The plurality of micro LEDs are transferred from a transfer substrate to the TFT layer by a laser beam radiated to the transfer substrate through openings of a mask. The openings correspond to regions in which the respective micro LEDs of the transfer substrate are arranged and the openings correspond to a width, a length, or a unit area of each of the micro LEDs.