Micro-LED Via Contact Structure for Higher Display Yield
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing micro-LED display apparatuses face challenges with low yield rates and increased repair needs due to the decreasing size of micro-LEDs and increasing display size, particularly when using the pick and place method.
Innovation Solution
A micro-LED display apparatus design featuring a driving circuit substrate with a first electrode, micro-LEDs, an insulating layer, a via pattern exposing the micro-LEDs, electrical contacts, and a second electrode, where the electrical contacts have a thickness corresponding to the distance between the insulating layer and the micro-LEDs, and are arranged in patterns such as dotted, stripe, or grid patterns, ensuring reliable connection and reduced defect rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the pick and place method is used to transfer micro-LEDs, then the manufacturing process is simple and flexible, but the yield rate decreases when micro-LED size decreases and display size increases
Solution Approach 1:
The invention divides the micro-LED transfer process into multiple stages: first transferring micro-LEDs to an intermediate substrate, then transferring them to the final display substrate. This segmentation allows for better control and inspection at each stage, improving overall yield rate while maintaining manufacturing flexibility.
Solution Approach 2:
The invention introduces an intermediate substrate as a mediator in the transfer process. The micro-LEDs are first transferred to this intermediate substrate, which serves as a buffer platform for inspection, sorting, and re-transfer, thereby improving yield rate without compromising the simplicity of the overall manufacturing approach.
2Area of stationary object
If the number of micro-LEDs increases to achieve larger display size, then the display area increases, but the transfer time increases and repair rate increases
Solution Approach 1:
The invention performs preliminary actions by transferring and inspecting micro-LEDs on an intermediate substrate before final placement. This allows for pre-sorting and pre-positioning, which reduces the time required for final transfer and minimizes the need for repairs later in the process.
Solution Approach 2:
The invention combines multiple functions (transfer, inspection, sorting, and positioning) into a single intermediate substrate platform. This merging of operations reduces the total time required compared to performing each function separately, while accommodating increased numbers of micro-LEDs for larger displays.
3Reliability
If micro-LEDs are transferred with higher precision to reduce defects, then the yield rate improves, but the manufacturing complexity increases
Solution Approach 1:
The invention segments the transfer process into distinct stages with the intermediate substrate serving as a control point. This allows for precision operations to be focused specifically at the transfer interface rather than throughout the entire process, maintaining high yield rate while limiting the spread of complexity.
Data Source
AI summary
The present disclosure provides a micro-light-emitting diode display apparatus and a method of manufacturing the same. Provided is a micro-light-emitting diode (LED) display apparatus including a plurality of pixels, the micro-LED display apparatus including a driving circuit substrate, a first electrode provided on the driving circuit substrate, one or more microlight-emitting diodes (LEDs) provided on the first electrode, an insulating layer provided on the one or more micro-LEDs, a via pattern provided in the insulating layer, electrical contacts provided in the via pattern, and a second electrode provided on the electrical contacts, wherein the via pattern exposes a portion of the one or more micro-LEDs.