Microstructured Component Transfer Using Stretchable Dicing Tape

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Solution Overview

Problem

There is a need for cost-effective and high-precision methods and systems to produce micro-LED displays and other microstructured components with a multiplicity of micro-functional elements on a substrate, as existing methods are inefficient in achieving economic fabrication while maintaining high quality.

Innovation Solution

The method involves using a dicing tape with an elastically stretchable base film and an adhesive layer as a transfer substrate, clamped in a clamping frame under surface tension, to temporarily fix and transfer micro-functional elements from a first substrate to a second substrate, utilizing laser processing for precise control and adhesion manipulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional transfer substrates are used for transferring micro-functional elements, then the transfer process can be performed, but the production efficiency and flexibility are limited

Engineering Contradiction:

Improveproduction efficiencyVSAvoidtransfer system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The dicing tape is elastically stretchable and can be dynamically adjusted in tension. The base film is stretched during mounting to ensure planarity and contact, then relaxed during transfer to enable easy release of micro-functional elements. This dynamic mechanical property allows the same substrate to serve multiple functions in different process stages, improving productivity without adding complex equipment.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If a dicing tape with adhesive layer is used as transfer substrate, then the flexibility and ease of operation improve, but the control of adhesion and release becomes more challenging

Engineering Contradiction:

Improveease of transfer operationVSAvoidprecision of adhesion control

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The adhesion parameters of the adhesive layer are precisely controlled by adjusting the mounting pressure and temperature. During mounting, high pressure ensures strong adhesion; during transfer, reduced pressure allows easy release. This parameter control enables the adhesive layer to provide both strong bonding and easy release functions, improving ease of operation while maintaining manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multiple transfer steps are used to achieve flexible arrangement, then the adaptability improves, but the process time and complexity increase

Engineering Contradiction:

Improveflexibility of arrangementVSAvoidtransfer process time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The dicing tape with adhesive layer serves multiple functions: it acts as a mounting substrate for picking up micro-functional elements, a transfer substrate for transporting them, and a release substrate for placing them on the target substrate. This multi-functionality eliminates the need for separate functional substrates for each transfer step, reducing process time while maintaining flexibility of arrangement.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Manufacturing precision

If elastically stretchable base film is used under surface tension, then the planarity and contact improve, but the device complexity increases

Engineering Contradiction:

Improveplanarity of transfer substrateVSAvoidclamping frame system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The elastically stretchable base film is a thin, flexible membrane that can be mounted on a simple clamping frame. When stretched, it becomes planar and maintains good contact with the micro-functional elements. The flexibility of the thin film allows it to conform to the clamping frame structure without requiring complex rigid support structures, achieving manufacturing precision with minimal device complexity.

Inventive Principle:

Principle #30Flexible shells and thin films

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 enables the cost-effective and high-precision transfer of micro-functional elements, allowing for flexible arrangement and increased production efficiency in micro-LED displays and other microstructured components, while maintaining the quality of the end product.

Implementation Method 1

an adhesive layer (104) attached to one side of the base film for temporarily fixing micro-functional units to the dicing tape

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

utilizing laser processing for precise control and adhesion manipulation

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS20240290909A1Method and system of producing microstructured components

Publication Date: 2024.08.29 3D MICROMAC AG

AI summary

A method and a system of producing a microstructured component includes a multiplicity of micro-functional elements on a substrate, wherein laser processing is carried out in at least one method stage in a laser processing station under the control of a control unit. One preferred field of application is the production of a micro-LED display including a substrate which carries an array of pixel-forming micro-light-emitting diodes arranged on an electrical supply structure arranged on the substrate.