Selective Adhesive Layer for Micro-LED Transfer Yield
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Solution Overview
Problem
The manufacturing of display devices using micro light-emitting elements is cumbersome and inefficient due to poor transfer yield and the need for multiple temporary substrates, as the process is difficult to perform well with small elements and requires high costs.
Innovation Solution
A display device with an adhesive layer having distinct first and second portions, where the first portion has higher adhesion and includes high refractive particles, and the second portion has lower adhesion, allowing for improved transfer yield by irradiating ultraviolet light before stamping to enhance adhesion in the first portion and reduce it in the second portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a micro light-emitting element is used to reduce display device size, then the size and weight of the display device are reduced, but the manufacturing time and cost increase due to the need for a large number of small elements
Solution Approach 1:
The adhesive layer is segmented into multiple regions with different adhesion strengths, allowing selective bonding of micro light-emitting elements to specific regions while enabling efficient transfer and reuse of the temporary substrate
Solution Approach 2:
The adhesion parameter of the adhesive layer is spatially varied by incorporating different materials or structures in different regions, creating areas of strong adhesion for element retention and areas of weak adhesion for substrate release and reuse
2Ease of manufacture
If stamping method is used to transfer micro light-emitting elements, then the transfer process can be performed, but the transfer yield deteriorates when the size of micro light-emitting elements becomes small
Solution Approach 1:
Different regions of the adhesive layer are designed with different adhesion characteristics, providing localized strong bonding in some areas and localized weak bonding in others, which enables precise control of the transfer process and high transfer yield for small elements
3Ease of manufacture
If a temporary substrate is used for stamping, then the transfer process can be performed, but the process becomes cumbersome because the temporary substrate cannot be reused and must be replaced after each stamping operation
Solution Approach 1:
The temporary substrate is designed to be recoverable and reusable by creating a controlled release mechanism through the differentiated adhesion regions, allowing the substrate to be released from non-adhesive areas and reused for multiple stamping operations, thereby reducing process complexity and cost
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 enables higher transfer yield and allows the reuse of temporary substrates, simplifying the manufacturing process and reducing costs by ensuring precise bonding of micro light-emitting elements to the first portion while preventing bonding to the second portion.
Implementation Method 1
an adhesive layer which includes a first portion and a second portion, wherein the first portion has higher adhesion than the second portion
Implementation Method 2
irradiating ultraviolet light onto a substrate on which an adhesive layer is positioned and pressing a stamp, on which a light-emitting element is positioned, on the substrate
Data Source
AI summary
Embodiments of the present disclosure relate to a display device and a method of manufacturing the same. More specifically, there may be provided includes a display device including an adhesive layer which includes a first portion and a second portion, wherein the first portion has higher adhesion than the second portion, and the second portion has lower adhesion than the first portion and includes high refractive particles so that a manufacturing process is simplified, and a method of manufacturing the same.