Electromagnetic Micro-LED Transfer for Selective Pattern Fidelity
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Solution Overview
Problem
The challenge in micro-LED (mLED) manufacturing lies in selectively transferring large numbers of mLED devices between substrates with varying heights and critical dimensions, requiring a transfer technology that is both selective and tolerant to manufacturing variabilities.
Innovation Solution
An electromagnetic apparatus with a body structure, isolation structures, and magnetic structures that utilize magnetic flux to selectively pick up and transfer mLED devices, ensuring pattern fidelity and adaptability to height variations by confining magnetic flux lines through the mLED devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional transfer methods are used, then transfer capability is achieved, but selectivity and tolerance to manufacturing variations deteriorate
Solution Approach 1:
The patent replaces conventional mechanical transfer methods with an electromagnetic field-based system. Electromagnetic fields are used to selectively actuate mLED devices for transfer, enabling precise control and selectivity while accommodating manufacturing variations in height and critical dimensions without relying on mechanical contact or positioning.
Solution Approach 2:
The patent utilizes changes in electromagnetic field parameters (such as frequency, amplitude, or distribution) to achieve selective actuation of mLED devices. By modulating these parameters, the system can selectively transfer specific mLED devices while tolerating variations in device geometry and positioning, thereby resolving the contradiction between selectivity and adaptability.
2Manufacturing precision
If selective transfer is implemented, then precision is improved, but device complexity increases
Solution Approach 1:
The electromagnetic apparatus is divided into multiple independent electromagnetic field sources or zones, each capable of selectively actuating specific mLED devices. This segmentation enables precise control over which devices are transferred while keeping each individual field source relatively simple, thus maintaining pattern fidelity without excessive overall complexity.
Solution Approach 2:
The electromagnetic transfer apparatus is designed to perform multiple functions: selective actuation, positioning, and transfer of mLED devices. By creating a multi-functional system, the patent reduces the need for separate specialized components, thereby achieving high manufacturing precision while managing device complexity through functional integration.
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
Enables the selective and efficient transfer of mLED devices across substrates, maintaining pattern fidelity and accommodating manufacturing variations, thereby enhancing the high-volume manufacturability of mLED-based displays.
Implementation Method 1
magnetic structures that utilize magnetic flux to selectively pick up and transfer mLED devices
Implementation Method 2
confining magnetic flux lines through the mLED devices
Data Source
AI summary
A magnetic apparatus includes a first structure including a first non-magnetic material, a second structure including a second non-magnetic material on a first portion of the first structure, a third structure including the second non-magnetic material on a second portion of the first structure. The magnetic apparatus further includes a first magnetic structure adjacent to a first sidewall of the second structure, a second magnetic structure adjacent to a first sidewall of the third structure, a third magnetic structure adjacent to a second sidewall of the second structure, adjacent to a second sidewall of the third structure and extends onto a third portion of the first structure. A magnet is coupled with the first, second and third magnetic structures.