Micro LED Laser Transfer Pressing Structure for Uniform Force
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Solution Overview
Problem
Conventional laser transfer methods for micro LEDs face issues with the bending of pressing members due to temperature and pressurizing force, leading to non-uniformity in the pressurizing force and potential manufacturing defects in the target substrate.
Innovation Solution
A manufacturing device with a support member and a mask member that includes a pressing member with a gas pressure regulator, ensuring uniform pressurizing force by controlling gas pressure in a sealed space, and a reflective light blocking pattern to protect the display substrate from laser light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressing member is used to pressurize the donor substrate during laser transfer, then the transfer of micro LEDs is enabled, but the pressing member bends due to temperature and pressurizing force causing non-uniform pressurizing force
Solution Approach 1:
The pressing member is divided into multiple independent pressing portions, each corresponding to a donor substrate. This segmentation allows each portion to independently apply pressure without affecting others, preventing deformation-induced non-uniformity and ensuring consistent transfer across multiple substrates.
Solution Approach 2:
A support member with openings is introduced as an intermediary structure between the pressing member and the donor substrates. This support member provides stable positioning and distributes the pressure uniformly, preventing the pressing member from bending while maintaining effective pressurization for micro LED transfer.
2Productivity
If laser light is irradiated to transfer micro LEDs, then the transfer process is achieved, but the display substrate is exposed to harmful laser light causing potential damage
Solution Approach 1:
The mask member is designed with selective transparency - it is transparent only in the regions corresponding to the donor substrates where micro LEDs need to be transferred, and opaque in other regions. This local quality differentiation allows laser light to pass through only where needed, enabling efficient transfer while protecting the display substrate from harmful laser exposure in non-transfer areas.
Solution Approach 2:
The mask member converts the potentially harmful laser light into a beneficial tool by selectively blocking it. The opaque portions of the mask block laser light from reaching areas of the display substrate that don't need micro LEDs, while the transparent portions allow laser light to facilitate the transfer process where needed.
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 device provides uniform pressurizing force, preventing manufacturing defects and improving efficiency by ensuring consistent transfer of micro LEDs to the target substrate.
Implementation Method 1
a pressing member with a gas pressure regulator, ensuring uniform pressurizing force by controlling gas pressure in a sealed space
Implementation Method 2
a reflective light blocking pattern to protect the display substrate from laser light
Data Source
AI summary
A manufacturing device of a display panel includes: a support portion on which a display substrate is mounted, a mask member disposed on a front surface of the support member and defining first openings corresponding to a transmission area of a laser light, a support member disposed on the display substrate and defining a plurality of second openings formed in an area corresponding to donor substrates disposed on the display substrate, respectively, a pressing portion including a pressing member for pressing the support member and the donor substrates disposed on the display substrate, and a laser irradiation portion disposed on an upper portion of the mask member for irradiating the laser light to light emitting elements of the donor substrates. The support member has a height equal to a sum of a thickness of each of the donor substrates and a height of each of the light emitting elements.