Micro LED Microcavities for Single-Step Transfer Alignment
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Solution Overview
Problem
Conventional methods for fabricating micro LED display panels require multiple transferring processes, leading to low alignment accuracy and poor display quality due to the separate fabrication and transfer of micro LEDs emitting different colors on different substrates.
Innovation Solution
A micro LED apparatus with a thin film transistor array substrate and microcavities of varying optical path lengths, allowing different colors to transmit through, enabling a single-step transfer of subpixels onto a target substrate, thereby enhancing transfer efficiency and reducing alignment errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro LEDs of different colors are fabricated and transferred separately on different substrates, then each color can be optimized independently, but alignment accuracy deteriorates and transfer efficiency decreases
Solution Approach 1:
The patent combines multiple microcavities of different colors (red, green, blue) onto a single substrate, forming a complete subpixel assembly before transfer. This merging approach eliminates the need for separate transfers of individual color micro LEDs, thereby improving alignment accuracy by ensuring all color elements are already positioned relative to each other and increasing transfer efficiency by reducing the number of transfer operations required.
Solution Approach 2:
The patent performs preliminary assembly of multi-color microcavities on the substrate before the final transfer step. By pre-positioning and assembling the microcavities of different colors on the same substrate in advance, the system ensures accurate alignment is achieved during the assembly phase, and this pre-assembled structure is then transferred as a complete unit, eliminating alignment issues that would arise from sequential transfers.
2Manufacturing precision
If multiple transferring processes are used for different colors, then each color can be transferred separately, but alignment errors increase and display quality deteriorates
Solution Approach 1:
The patent merges the transfer processes for different colors into a single transfer operation by assembling all color microcavities on one substrate. This reduces the device complexity by eliminating multiple separate transfer processes and their associated alignment mechanisms, while simultaneously improving alignment accuracy since all elements are transferred together as a unified structure.
3Illumination intensity
If microcavities of different optical path lengths are used for different colors, then color-specific transmittance is improved, but structural complexity increases
Solution Approach 1:
The patent applies local quality by assigning specific optical path lengths to microcavities based on their color function. Each microcavity is designed with a tailored optical path length optimized for its specific color wavelength, allowing maximum transmittance for the intended color while blocking others. This localized optimization achieves high color purity and transmittance without requiring the entire structure to be complex, as each element is simply optimized for its specific purpose.
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 allows for a full-color display panel to be formed in a single step, improving transfer efficiency and reducing alignment errors, while maintaining high transmittance rates for specific colors.
Implementation Method 1
a first microcavity having a first optical path length and a second microcavity having a second optical path length different from the first optical path length; the first microcavity is configured to allow a light of a first color to transmit there-through; and the second microcavity is configured to allow a light of a second color to transmit there-through
Data Source
AI summary
A micro light emitting diode (micro LED) apparatus. The micro LED apparatus includes a thin film transistor array substrate including a plurality of thin film transistors; an array of a plurality of micro LEDs on the thin film transistor array substrate, a respective one of the plurality of micro LEDs being connected to a respective one of the plurality of thin film transistors; and a plurality of microcavities respectively on a side of the plurality of micro LEDs away from the thin film transistor array substrate. The plurality of microcavities include a first microcavity having a first optical path length and a second microcavity having a second optical path length different from the first optical path length. The first microcavity is configured to allow a light of a first color to transmit there-through. The second microcavity is configured to allow a light of a second color to transmit there-through.