Micro-LED Transfer Using Solvent Release and Fluidic Self-Assembly
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Solution Overview
Problem
The existing methods for manufacturing large-size micro LED displays face challenges in productivity and economic feasibility due to the complexity of transferring micro LEDs to pixel positions using the pick-and-place method, which limits the implementation of high-quality images and efficient energy use.
Innovation Solution
A method involving fluidic self-assembly (FSA) using a penetrating solvent that is vaporized by radiating light to transfer micro LEDs from an interposer to a driving substrate, combined with roll-to-roll and step-and-repeat processes for efficient large-scale production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pick-and-place method is used to transfer micro LEDs to pixel positions, then the transfer process can be performed, but productivity is difficult to guarantee and manufacturing cost increases
Solution Approach 1:
The patent replaces the mechanical pick-and-place transfer method with a fluidic self-assembly process. Micro LEDs are transferred using fluid flow and capillary forces through an interposer structure, eliminating complex mechanical positioning systems and significantly improving productivity while reducing manufacturing complexity
Solution Approach 2:
The patent introduces an interposer as an intermediary component between the micro LED array and the driving substrate. The interposer facilitates automated transfer through fluidic pathways and alignment features, enabling high-speed manufacturing without direct mechanical manipulation of each micro LED
2Manufacturing precision
If the pick-and-place method is used for micro LED transfer, then positioning can be achieved, but economic feasibility deteriorates
Solution Approach 1:
The patent replaces expensive mechanical pick-and-place systems with a fluidic self-assembly process that achieves precise positioning through capillary forces and alignment features built into the interposer, significantly reducing manufacturing cost while maintaining positioning precision
Solution Approach 2:
The patent pre-configures the interposer with alignment features, fluid pathways, and well structures before the transfer process. This preliminary preparation enables automated, high-precision positioning of micro LEDs without requiring complex real-time control systems, reducing both cost and complexity
3Productivity
If traditional manufacturing methods are used, then production can proceed, but energy efficiency is low and high-quality image implementation is limited
Solution Approach 1:
The patent replaces energy-intensive mechanical transfer systems with a fluidic self-assembly process that uses minimal energy to drive fluid flow and capillary forces, significantly improving manufacturing energy efficiency while enabling high-speed production of large-size displays
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 enables faster and more economical manufacturing of large-size micro LED displays with improved energy efficiency and high-quality image implementation by ensuring precise alignment and transfer of micro LEDs, overcoming the limitations of traditional methods.
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
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.