Selective Adhesive Layer Layout for Light-Emitting Element Transfer
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Solution Overview
Problem
Existing display devices face challenges in efficiently transferring light-emitting elements during manufacturing, particularly in achieving precise adhesion and reducing transfer time and defects.
Innovation Solution
A display device and manufacturing method where only specific portions of the adhesive layer have adhesive force, allowing for selective transfer of light-emitting elements to sub-pixels, and enabling consecutive transfer processes using a single donor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the entire adhesive layer has adhesive force, then all light-emitting elements are transferred, but it is impossible to achieve selective transfer to specific sub-pixels
Solution Approach 1:
The adhesive layer is segmented into multiple regions with different adhesive properties: a first adhesive region with strong adhesion for transferring light-emitting elements, a second adhesive region with weak adhesion for elements to remain on the donor, and a third adhesive region with medium adhesion. This segmentation enables selective transfer of specific light-emitting elements to corresponding sub-pixels while maintaining a relatively simple overall adhesive layer structure.
Solution Approach 2:
Different portions of the adhesive layer are assigned different adhesive strengths tailored to specific functional requirements. The first adhesive region has enhanced adhesion for target elements, while the second adhesive region has reduced adhesion to prevent unwanted transfer. This local differentiation of adhesive quality achieves precise selective transfer without requiring complex external control mechanisms.
2Productivity
If multiple transfer processes are performed to transfer all light-emitting elements, then complete transfer is achieved, but the manufacturing time increases
Solution Approach 1:
The adhesive layer is pre-configured with multiple regions of different adhesive strengths before the transfer process begins. This preliminary preparation allows all light-emitting elements to be transferred in a single process by simply controlling the peeling direction and sequence, eliminating the need for multiple repeated transfer operations and significantly reducing manufacturing time.
Solution Approach 2:
The adhesive layer's effective adhesion is dynamically controlled through the peeling process. By peeling the donor substrate in a specific direction, elements in the first adhesive region are transferred while elements in the second adhesive region remain on the donor. This dynamic control of adhesion during peeling enables complete transfer in one operation rather than requiring multiple static transfer steps.
3Manufacturing precision
If the adhesive layer is peeled in any direction, then transfer occurs, but precise control over which elements are transferred is lost
Solution Approach 1:
The adhesive layer incorporates regions with locally optimized adhesive properties. The first adhesive region has strong adhesion specifically oriented for transfer in the peeling direction, while the second adhesive region has weak adhesion that prevents transfer. This local quality differentiation ensures that when peeling occurs in the designated direction, only the desired light-emitting elements are transferred with high precision, while the operation remains simple as it only requires peeling in one direction.
4Strength
If the adhesive force is uniformly strong across the entire layer, then all elements adhere firmly, but selective release and transfer becomes difficult
Solution Approach 1:
The adhesive layer is divided into segments with different adhesive strengths: a first adhesive region with strong adhesion for firm holding and selective release, and a second adhesive region with weak adhesion for easy release. This segmentation provides both strong adhesion where needed and selective release capability where required, enabling precise control over which elements are transferred without compromising overall adhesion strength.
Solution Approach 2:
Different adhesive strengths are applied locally to different regions of the adhesive layer. The first adhesive region maintains strong adhesion for elements that need to be firmly held and selectively transferred, while the second adhesive region has reduced adhesion for elements that should remain on the donor. This local quality differentiation achieves both strong overall adhesion and selective transfer capability.
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 simplifies the transfer process, reduces time, and minimizes defects by ensuring precise adhesion and selective transfer of light-emitting elements to their intended sub-pixels.
Implementation Method 1
only a portion of an adhesive layer to which a light-emitting element is to be transferred in a transfer process has an adhesive force
Data Source
AI summary
A display device may include a substrate on which pixels are defined, each pixel including a plurality of sub-pixels; a step formation layer disposed on the substrate; an adhesive layer disposed on the step formation layer; and a plurality of light-emitting elements respectively disposed in the plurality of sub-pixels, and disposed on the adhesive layer. The adhesive layer may include: a plurality of first portions respectively overlapping the light-emitting elements, a plurality of non-adhering areas respectively disposed adjacent to the plurality of first portions; and a second portion other than the plurality of first portions and the plurality of non-adhering areas. Accordingly, a transfer process may be simplified, and a transfer process time may be reduced. A method for manufacturing the display device is also disclosed.