Spherical Flip-Chip Micro-LED Structure for High-Yield Mass Transfer
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Solution Overview
Problem
The challenge in forming micro LED arrays lies in the difficulty of mass transferring small, spherical LEDs with a predetermined size due to their structure, which limits light-emitting area and efficiency, as conventional LEDs are prone to getting stuck outside loading wells during transfer and have limited epitaxial layer thickness.
Innovation Solution
A spherical flip-chip micro-LED is developed, comprising a light-emitting body, a transparent supporting body, and an insulating protective layer, forming a complete spherical structure that ensures normal light emission and facilitates high-efficiency mass transfer by maintaining a tumbler-like structure for easier alignment and embedding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional rectangular or cylindrical LED structures are used, then the manufacturing process is simple, but the LEDs fail to be embedded in the loading wells during fluidic assembly
Solution Approach 1:
The patent transforms the conventional rectangular or cylindrical LED structure into a spherical structure. This curvature change enables the LEDs to roll and align properly during fluidic assembly, allowing them to be embedded in the loading wells of the substrate, thereby resolving the transfer efficiency problem while maintaining manufacturing feasibility through standard spherical fabrication processes
2Area of stationary object
If the thickness of LED epitaxial layer is increased to improve light-emitting area, then the light-emitting area increases, but the spherical structure size becomes too large for efficient mass transfer
Solution Approach 1:
The patent divides the LED structure into two functional segments: a spherical light-emitting body with controlled thickness for efficient mass transfer, and a separate planar supporting body that provides the necessary light-emitting area. This segmentation allows the spherical portion to maintain small size for high-speed fluidic assembly while the supporting body extends the functional light-emitting surface area independently
3Productivity
If a spherical structure is formed to improve fluidic assembly efficiency, then the transfer efficiency improves, but the light-emitting area is limited by epitaxial layer thickness
Solution Approach 1:
The patent transitions from a two-dimensional light-emitting surface to a three-dimensional structure by adding a separate planar supporting body beneath the spherical light-emitting body. This dimensional extension allows the light-emitting area to increase in the vertical dimension without affecting the spherical size that determines transfer efficiency during fluidic assembly
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
The spherical structure enhances light-emitting efficiency and transfer yield by ensuring accurate alignment and embedding of micro-LEDs, improving production efficiency and luminous performance while maintaining a predetermined size and light-emitting area.
Implementation Method 1
a light-emitting body 1, a supporting body 2, a first electrode 3, a second electrode 4, and an insulating protective layer 5. The first electrode 3 and the second electrode 4 are electrically coupled to the light-emitting body 1
Implementation Method 2
a supporting body 2, such as a transparent supporting body 2
Data Source
AI summary
A spherical flip-chip micro-LED, a method for manufacturing the spherical flip-chip micro-LED, and a display panel are provided. The spherical flip-chip micro-LED includes a light-emitting body, a supporting body, a first electrode, a second electrode, and an insulating protective layer. The supporting body is transparent. The first electrode and the second electrode are electrically coupled with the light-emitting body. The insulating protective layer covers the light-emitting body. The light-emitting body, the supporting body, and the insulating protective layer form a spherical structure.