Optical Layer Convex Lens Transfer for LED Alignment
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Solution Overview
Problem
The capture yield of LED elements during transfer processes for LED display panels is compromised due to uneven downward pressure, leading to a high risk of LED elements falling off or misalignment, which affects the fabrication yield and light emitting efficiency.
Innovation Solution
An electronic device comprising a driving-circuit substrate, light-emitting elements, and an optical layer with convex lens structures and an adhesive layer, where the light-emitting elements are bonded to the optical layer using the adhesive layer, allowing for precise transfer and alignment onto the driving-circuit substrate without removing the optical layer, thereby preventing falling off and misalignment, and utilizing the optical layer as a light condensing device to enhance light emitting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional transfer technology is used to transfer LED elements to target substrate, then the transfer process can be completed, but the capture yield of LED elements decreases due to uneven downward pressure
Solution Approach 1:
The optical layer is designed with convex lens structures that have curved surfaces. These convex lenses concentrate downward pressure onto the LED elements through their curved geometry, ensuring uniform pressure distribution across each element's surface. This curvature-based pressure concentration resolves the uneven pressure problem in traditional flat transfer methods, improving both capture yield and alignment precision.
Solution Approach 2:
An optical layer with convex lens structures is introduced as an intermediary component between the pressing mechanism and the LED elements. This intermediary layer distributes and concentrates pressure uniformly through its lens structures, preventing direct uneven contact between the pressing tool and LED elements. The optical layer acts as a mediator that transforms irregular pressure into uniform pressure distribution, thereby improving transfer reliability.
2Reliability
If LED elements are transferred using conventional methods, then transfer can be achieved, but the risk that LED elements fall off during movement increases
Solution Approach 1:
The convex lens structures with curved surfaces create enhanced contact area and pressure concentration points on LED elements during bonding. The curved geometry ensures that pressure is applied uniformly across the element surface, creating stronger and more reliable bonds. This prevents elements from falling off during subsequent handling and assembly processes, improving both bonding reliability and overall fabrication yield.
Solution Approach 2:
The optical layer with convex lenses provides a cushioning effect during the bonding process. The curved surfaces of the lenses distribute pressure gradually and uniformly, preventing sudden stress concentrations that could cause element damage or poor bonding. This prior cushioning approach ensures reliable bonding before elements are subjected to subsequent handling and assembly stresses.
3Use of energy by moving object
If optical layer is removed after LED element transfer, then transfer process is complete, but light emitting efficiency decreases
Solution Approach 1:
The optical layer with convex lens structures serves multiple functions: it acts as a transfer medium during the bonding process and simultaneously functions as a light extraction and condensing structure after bonding. The convex lenses are designed to optimize light emission by controlling light extraction angles and reducing total internal reflection. This multi-functionality eliminates the need for separate light management components, maintaining high light emitting efficiency while avoiding additional structural complexity.
Solution Approach 2:
The transfer function and light management function are merged into a single optical layer component. The convex lens structures that facilitate uniform pressure distribution during transfer also serve as light extraction and condensing elements after bonding. By combining these functions into one integrated structure, the design achieves high light emitting efficiency without adding separate components, thus avoiding increased device complexity.
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 improves the fabrication yield by preventing LED element loss and misalignment, while also enhancing light emitting efficiency by maintaining the optical layer on the elements post-transfer and using it for light condensation.
Implementation Method 1
An adhesive layer is directly used to bond the light-emitting elements on an optical layer
Implementation Method 2
the optical layer is still kept on the light-emitting elements (and does not need to be removed), and is used as a light condensing device of the light-emitting elements, thereby improving light emitting efficiency
Data Source
AI summary
The present invention provides an electronic device and a method for fabricating the same. The electronic device includes a driving-circuit substrate, light-emitting elements, an optical layer, and an adhesive layer. The light-emitting elements are disposed on the driving-circuit substrate, and the optical layer is disposed on the light-emitting elements. The adhesive layer is disposed between the optical layer and the light-emitting elements. The optical layer includes a first surface and a second surface that are opposite to each other. The first surface of the optical layer has a plurality of first convex lens structures, and at least a part of the first convex lens structures are at least partially overlapped with the light-emitting elements in the vertical projection direction.