Micro-LED Transfer Using FSA and Solvent Vapor Release
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Solution Overview
Problem
The existing methods for manufacturing micro LED displays, particularly large-size displays, face challenges in productivity and economic feasibility due to the complexity and inefficiency of the pick-and-place method used for transferring micro LEDs.
Innovation Solution
A method involving a roll-to-roll, step and repeat, or laser scanning process to manufacture large-size micro LED displays, utilizing a fluidic self-assembly (FSA) process to transfer micro LEDs onto a driving substrate, with the aid of a penetrating solvent or a laser active blister layer for precise alignment and transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pick-and-place method is used to transfer micro LEDs, then positioning precision is achieved, but productivity is poor and manufacturing cost is high
Solution Approach 1:
The patent replaces the mechanical pick-and-place transfer method with a fluidic self-assembly (FSA) process. Micro LEDs are transferred using fluid flow and capillary forces rather than mechanical grippers and placement mechanisms. This substitution enables parallel transfer of multiple micro LEDs simultaneously, dramatically improving productivity while maintaining positioning precision through the structured fluidic environment and capillary wells.
Solution Approach 2:
The patent employs hydraulic principles in the FSA process where a liquid carrier fluid transports micro LEDs to the target substrate. The fluid flow dynamics and capillary pressure in the wells enable precise positioning and transfer of micro LEDs without mechanical contact, achieving both high productivity and positioning accuracy through fluid-based manipulation.
2Manufacturing precision
If pick-and-place method is used to transfer micro LEDs, then positioning precision is achieved, but manufacturing cost is high
Solution Approach 1:
The patent replaces expensive mechanical pick-and-place equipment with a simpler fluidic self-assembly system. The FSA process uses basic fluid handling equipment and capillary structures instead of complex robotic manipulators, significantly reducing manufacturing equipment costs while maintaining positioning precision through the self-organizing fluidic environment.
Solution Approach 2:
The patent implements self-service through the self-assembly nature of the FSA process. Micro LEDs automatically position themselves in the capillary wells driven by fluid flow and surface tension forces without requiring complex control systems or expensive positioning equipment. This self-organizing behavior reduces manufacturing complexity and cost while achieving precise positioning.
3Productivity
If conventional transfer method is used, then micro LED transfer is achieved, but transfer efficiency is low
Solution Approach 1:
The patent merges multiple transfer operations into a single parallel FSA process. Instead of transferring micro LEDs one by one or in small batches, the fluidic system simultaneously transports and positions multiple micro LEDs across the substrate in one operation. This merging of transfer operations dramatically increases transfer efficiency and reduces total manufacturing time.
Solution Approach 2:
The patent achieves continuous transfer action through the flowing fluid carrier that continuously transports micro LEDs from the source to the target substrate. The fluid flow maintains constant motion and transfer capability throughout the process, eliminating idle time between transfers and enabling sustained high-speed manufacturing operations.
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 method enhances the productivity and economic feasibility of manufacturing large-size micro LED displays by improving the efficiency of micro LED transfer and alignment, allowing for faster production speeds and larger display areas without the need for tiling.
Implementation Method 1
a third operation of injecting a penetrating solvent between the interposer and the driving substrate, such that the penetrating solvent penetrates between the plurality of micro LEDs and the plurality of wells
Implementation Method 2
a fourth operation of transferring the plurality of micro LEDs to the driving substrate by radiating light to the interposer to vaporize the penetrating solvent
Implementation Method 3
a fourth operation of transferring the plurality of micro LEDs to the driving substrate by radiating light to the interposer to vaporize the penetrating solvent
Data Source
AI summary
Provided is a method of manufacturing a display, the method including a first operation of transferring a plurality of micro light emitting diodes (LEDs) to a plurality of wells of an interposer through a fluidic self assembly (FSA) process, a second operation of aligning a driving substrate on the interposer, a third operation of injecting a penetrating solvent between the interposer and the driving substrate, such that the penetrating solvent penetrates between the plurality of micro LEDs and the plurality of wells, and a fourth operation of transferring the plurality of micro LEDs to the driving substrate by radiating light to the interposer to vaporize the penetrating solvent.