Micro LED Transfer Structure for High-Resolution Display Assembly
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Solution Overview
Problem
The challenge lies in efficiently mounting and transferring a large number of small micro LEDs onto a display panel substrate, as their small size makes handling and mounting difficult.
Innovation Solution
A method of manufacturing a displaying apparatus that involves forming light emitting devices on a growth substrate, then using a series of mask layers and connection layers to facilitate their transfer onto a display panel substrate, with temporary substrates used to support the devices during the separation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If micro LEDs are made smaller to increase pixel density, then the display resolution is improved, but the handling and mounting difficulty increases
Solution Approach 1:
The patent segments the micro LEDs from their growth substrate using mask layers and connection layers, allowing individual micro LEDs to be separated and mounted independently while maintaining their small size for high resolution displays
Solution Approach 2:
The patent introduces mask layers and connection layers as intermediary structures between the growth substrate and the display panel substrate. These intermediary layers facilitate the transfer and mounting of micro LEDs without requiring direct handling of the tiny devices themselves
2Measurement precision
If a large number of micro LEDs are arranged on one substrate, then the display quality is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent divides the manufacturing process into distinct stages: growth substrate preparation, mask layer formation, connection layer formation, and transfer to display panel substrate. This segmentation allows each stage to be optimized independently, managing the complexity of producing large numbers of micro LEDs
Solution Approach 2:
The patent performs preliminary actions by forming mask layers and connection layers on the growth substrate before transferring the micro LEDs. This preliminary preparation simplifies the subsequent transfer process and reduces manufacturing complexity during the actual mounting stage
3Ease of manufacture
If conventional mounting methods are used for micro LEDs, then the process is simple, but the transfer safety and efficiency deteriorate
Solution Approach 1:
The patent uses mask layers and connection layers as intermediary structures that securely hold the micro LEDs during transfer. This intermediary approach ensures safe transfer of the fragile tiny devices while maintaining a relatively simple overall process flow
Solution Approach 2:
The patent performs preliminary actions by forming protective mask layers and connection layers before transfer. This preliminary protection ensures transfer safety without significantly complicating the manufacturing process
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.