Micro-LED Transfer Substrate With Self-Alignment Traps
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Solution Overview
Problem
The existing pick and place method for transferring micro LEDs in display devices is inefficient as the size of micro LEDs decreases and display sizes increase, leading to low productivity in manufacturing.
Innovation Solution
A display transferring structure with a transfer substrate featuring recesses designed for fluid self-alignment, including first, second, and optional third traps, where micro-semiconductor chips are seated and aligned with precision, allowing for efficient positioning on a large substrate, and a driving circuit for chip operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pick and place method is used for transferring micro LEDs, then micro LEDs can be positioned on display substrate, but productivity decreases as micro LED size decreases and display size increases
Solution Approach 1:
The recess structure enables self-alignment of micro LEDs through geometric constraints. The first trap provides initial positioning while the second trap secures the final position, allowing micro LEDs to automatically align without complex external positioning systems, thereby maintaining high precision while improving productivity
Solution Approach 2:
The recess is divided into multiple functional zones (first trap and second trap) that perform different alignment functions. This segmentation allows the system to achieve both coarse and fine alignment in a single transfer process, improving productivity without sacrificing precision
2Manufacturing precision
If micro LED size decreases, then display resolution improves, but transfer efficiency and productivity deteriorate
Solution Approach 1:
The geometric design of the recess with its two-stage trap structure enables self-alignment of miniaturized LEDs. This eliminates the need for complex positioning equipment that would slow down mass transfer, maintaining high productivity even as LED sizes decrease for higher display resolution
Solution Approach 2:
The recess dimensions and trap configurations are specifically optimized for small-scale micro LEDs. By adjusting the geometric parameters of the recess structure, the system maintains effective alignment functionality even when transferring extremely small LEDs, thus supporting higher display resolution without losing transfer efficiency
Data Source
AI summary
A display transferring structure includes a transfer substrate including a plurality of recesses, each of the plurality of recesses including a first trap having a space in which a predetermined object can be moved and a second trap connected to the first trap and having a shape and size in which the object can be seated; and a micro-semiconductor chip positioned in the second trap. The micro-semiconductor chip may be self-aligned in a correct position by the display transferring structure.