Spacer Layout for Precise Micro-LED Transfer and Light Isolation
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Solution Overview
Problem
The existing methods for transferring light-emitting units, such as LEDs, in electronic device manufacturing face challenges in achieving precise positioning and reducing light mixing between adjacent elements, leading to insufficient display quality and increased costs due to inefficient transfer processes.
Innovation Solution
The use of a substrate with strategically arranged spacers to separate regions for light-emitting elements, allowing for exact positioning and reducing the impact of adjacent elements, thereby improving light quality and enabling selective repair of subpixel regions to minimize the number of elements that need to be transferred.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light-emitting elements are transferred using existing methods, then the transfer process can be completed, but precise positioning is difficult to achieve and light mixing between adjacent elements occurs
Solution Approach 1:
A spacer structure is introduced as an intermediary element between adjacent light-emitting elements. The spacer includes a first region and a second region with different refractive indices, creating an optical barrier that prevents light mixing while maintaining precise positioning of the light-emitting elements during transfer.
Solution Approach 2:
The spacer is segmented into multiple regions with different optical properties. The first region and second region are divided along the light propagation direction, allowing differential control of light paths from adjacent elements and enabling precise positioning without light interference.
2Reliability
If all light-emitting elements are transferred to ensure display quality, then good display quality is achieved, but the cost increases due to inefficient transfer processes
Solution Approach 1:
The spacer provides localized optical isolation between adjacent light-emitting elements. This local quality improvement allows certain elements to be selectively transferred or repaired without compromising overall display quality, reducing manufacturing costs by avoiding unnecessary transfers of all elements.
3Area of moving object
If adjacent light-emitting elements are placed close together to increase density, then the display resolution improves, but light mixing between elements occurs
Solution Approach 1:
The spacer acts as an optical intermediary between closely spaced light-emitting elements. By positioning the spacer between adjacent elements and utilizing its multi-region structure with different refractive indices, light mixing is prevented even when elements are placed at high density, maintaining both resolution and optical quality.
Data Source
AI summary
An electronic device includes a substrate, a spacer, a first element and a second element. A spacer is disposed on the substrate and has a first opening, a second opening and a third opening arranged in a first direction. The second opening is located between the first opening and the third opening. A distance between the first opening and the second opening is less than a distance between the second opening and the third opening in the first direction. A first element is located in at least one of the first opening and the second opening. A second element is located in the third opening.