Micro-LED Groove Assembly for Precise Large-Area Display Transfer
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Solution Overview
Problem
The challenge of transferring millions of micro-sized semiconductor light emitting devices for large-screen displays is hindered by low transfer precision and yield, especially when using self-assembly methods, which is crucial for high-definition displays.
Innovation Solution
A manufacturing process involving a base part with grooves and electrodes, utilizing a magnetic field and electric field to self-assemble semiconductor light emitting devices on a substrate, minimizing the influence of gravity and friction, and enabling selective assembly without additional devices or processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pick & place method is used to transfer semiconductor light emitting devices, then transfer precision can be improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The semiconductor light emitting devices perform self-assembly through self-propulsion in fluid using catalytic reactions. The devices autonomously navigate to target positions on the substrate and assemble themselves without requiring complex external manipulation equipment, thereby achieving high transfer precision while simplifying the manufacturing process
Solution Approach 2:
The patent replaces mechanical transfer methods (pick & place) with a chemical-biological propulsion system. Semiconductor light emitting devices are equipped with catalytic structures that generate self-propulsion in fluid through catalytic reactions, enabling autonomous transport to target positions without mechanical handling equipment
2Productivity
If laser lift-off method is used for transfer, then transfer speed can be improved, but manufacturing precision and device reliability deteriorate
Solution Approach 1:
Devices autonomously navigate to target positions through self-propulsion in fluid, eliminating the need for high-speed laser processing while maintaining precise positioning through catalytic navigation and fluid flow control
Solution Approach 2:
The patent uses fluid dynamics to transport semiconductor light emitting devices. Devices self-propel through fluid to target positions on the substrate, utilizing fluid flow control and catalytic reactions in fluid environment to achieve both high speed and high precision transfer without laser processing
3Device complexity
If self-assembly method is used, then device complexity is reduced, but transfer precision and manufacturing reliability worsen
Solution Approach 1:
The patent enhances self-assembly by equipping devices with active self-propulsion capabilities through catalytic structures. Devices autonomously navigate to target positions using catalytic reactions in fluid, achieving high transfer precision while maintaining manufacturing process simplicity
Solution Approach 2:
The patent changes the state of semiconductor light emitting devices by introducing catalytic structures that enable self-propulsion in fluid. This parameter change transforms passive devices into active self-navigating units, improving transfer precision while maintaining the simplicity of self-assembly
4Measurement precision
If semiconductor light emitting device size is reduced for high-definition display, then display resolution is improved, but transfer yield and manufacturing precision worsen
Solution Approach 1:
Even miniaturized semiconductor light emitting devices maintain self-propulsion capabilities through integrated catalytic structures. The self-navigating ability allows precise positioning and high-yield assembly of small devices that would be difficult to handle with conventional transfer methods
Solution Approach 2:
Fluid-based self-propulsion enables precise control and transport of miniaturized semiconductor light emitting devices. The fluid environment provides gentle handling and precise positioning for small devices, maintaining high transfer yield while enabling high-definition display requirements
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 allows for high-yield, low-cost, and high-speed transfer of semiconductor light emitting devices to large-area substrates, facilitating high-definition displays by ensuring precise positioning and reducing non-specific binding.
Implementation Method 1
a magnetic field and electric field to self-assemble semiconductor light emitting devices on a substrate
Implementation Method 2
a magnetic field and electric field to self-assemble semiconductor light emitting devices on a substrate
Data Source
AI summary
The present invention relates to a display apparatus, specifically to a display apparatus using semiconductor light-emitting elements of a few micrometers to tens of micrometers in size. The present invention provides a display apparatus comprising: a base part; a partition part having a plurality of grooves; a plurality of semiconductor light-emitting elements arranged on the base part and mounted in the plurality of grooves; first and second wiring electrodes arranged on one side and the other side of each of the semiconductor light-emitting elements, respectively; an assembly electrode arranged on the base part and arranged on the one side of each of the semiconductor light-emitting elements; and a dielectric layer arranged on the base part and arranged between the assembly electrode and the first wiring electrode, wherein each of the plurality of grooves includes at least one recess portion formed in the horizontal direction with respect to the base part.