Micro LED Transfer Strips With Holding Cells For Array Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The transfer process of micro light emitting diodes (micro LEDs) to a target substrate is complex and time-consuming, and it is difficult to detect and repair defective micro LEDs during conventional transferring processes.
Innovation Solution
A method involving transfer strips with holding cells and alignment marks, where micro LEDs are aligned and adhered to form arrays, and defective LEDs can be removed and reassembled, using cutting grooves to sever and reattach the strips, facilitating efficient transfer and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional transfer processes are used, then micro LEDs can be transferred to target substrate, but the process is complex and time-consuming
Solution Approach 1:
The invention divides the transfer process into distinct stages: (1) transferring micro LEDs to holding cells on transfer strips, (2) aligning multiple transfer strips to form arrays, and (3) severing holding cells to create micro LED strips. This segmentation simplifies each individual step while maintaining overall transfer efficiency and enabling parallel processing of multiple strips simultaneously.
2Ease of repair
If conventional transfer processes are used, then micro LEDs can be transferred, but it is difficult to detect and repair defective micro LEDs
Solution Approach 1:
The invention performs preliminary detection and repair actions while micro LEDs are still on the transfer strips before final array formation. Holding cells provide isolated compartments that allow individual defective LEDs to be identified and replaced without affecting other LEDs. This preliminary repair approach is much easier than post-assembly repair and significantly reduces detection and measurement difficulty.
3Productivity
If multiple transfer strips are aligned to form arrays, then micro LED arrays can be formed efficiently, but precise alignment is required
Solution Approach 1:
The invention introduces holding cells as intermediary structures that facilitate precise alignment. Each holding cell contains a micro LED at a predetermined position, and multiple transfer strips with holding cells can be aligned relative to each other through the holding cell structures. This intermediary mechanism enables efficient array formation while maintaining the required alignment precision.
Data Source
AI summary
A method of transferring a plurality of mero light emitting diodes (micro LEDs) to a target substrate s provided. The method includes providing a plurality of transfer strips, a respective one of the plurality of transfer strips including a plurality of holding cells sequentially arranged along a first direction; transferring a plurality of micro LEDs onto the plurality of holding cells of the plurality of transfer strips; and aligning the plurality of transfer strips having the plurality of micro LEDs transferred thereon with respect to each other, to form an array of micro LEDs in which micro LEDs from different transfer strips of the plurality of transfer strips we aligned along a second direction and micro LEDs from a same transfer strip of the plurality of transfer strips are aligned along the first direction, the second direction being different from the first direction.