Roller Transfer Device With Stamp Contacts For Large Substrates
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Solution Overview
Problem
Current micro-electronic transfer methods have low efficiency and are unable to transfer elements onto substrates of large size effectively.
Innovation Solution
A transfer device comprising a first conveyance roller, a transfer roller with stamp contacts, and a second conveyance roller, where the rollers are arranged in parallel with a medium substrate and a target substrate interposed between them, allowing for efficient transfer of elements from a medium substrate to a larger target substrate through coordinated rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional stamp transfer method is used, then transfer process is simple, but transfer efficiency is low and cannot handle large size substrates
Solution Approach 1:
The transfer device is segmented into multiple functional modules: first conveyance roller for substrate input, transfer roller with stamp contacts for element transfer, second conveyance roller for substrate output, and cleaning mechanism for maintenance. Each module performs a specific function, allowing the system to achieve high transfer efficiency while maintaining manageable complexity through modular design.
2Area of stationary object
If traditional stamp transfer method is used, then equipment structure is simple, but cannot transfer elements onto large size substrates
Solution Approach 1:
The invention transitions from traditional planar stamp transfer to a three-dimensional roller-based system. The rollers are arranged in parallel with their axes extending in one direction, creating a dimensional expansion that enables transfer across larger substrate areas while maintaining a compact device footprint through the cylindrical geometry of the rollers.
3Productivity
If roller-based transfer system is implemented, then transfer efficiency improves, but device complexity increases
Solution Approach 1:
The transfer roller serves multiple functions: it conveys the medium substrate through the first roll gap, transfers elements via its stamp contacts, and conveys the target substrate through the second roll gap. This multi-functionality reduces the need for separate dedicated components, thereby improving transfer efficiency while limiting the increase in device complexity.
Solution Approach 2:
The cleaning mechanism is designed to automatically clean the transfer roller without requiring manual intervention or complex disassembly. The cleaning unit can be integrated into the roller system, allowing the transfer roller to maintain its functionality autonomously and reducing the operational complexity of the overall device.
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 transfer of a large number of elements from a medium substrate to a target substrate of larger size with improved efficiency and accuracy, using dimethyl silicone polymer stamp contacts for effective absorption and transfer.
Implementation Method 1
a plurality of first stamp contacts (220) formed on and protruded from a peripheral surface of the roller body (210), the first stamp contacts (220) being able to absorb elements to be transferred (400)
Implementation Method 2
the first stamp contacts (220) are made of dimethyl silicone polymer
Data Source
AI summary
A transfer device and a transfer method using the same. The transfer device comprises a first conveyance roller, a transfer roller and a second conveyance roller. The transfer roller includes a roller body and stamp contacts formed on and protruded from the roller body. The stamp contacts can absorb elements, axes of the first conveyance roller. The transfer roller and the second conveyance roller are arranged in parallel with each other. The transfer roller is interposed between the first and second conveyance rollers. A first roll gap is formed between the first conveyance roller and the transfer roller to convey a medium substrate, and a second roll gap is formed between the second conveyance roller and the transfer roller to convey a target substrate. The transfer device and method can be used to transfer a great amount of elements to the substrate having large size.