Stamped Micro LED Transfer With Magnetic Polymer Interconnects
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pick-and-place transferring processes are inefficient for high-resolution and large-area micro LED displays due to mechanical precision limitations and the need for precise arrangement of millions of LED elements, which becomes increasingly challenging with miniaturization.
Innovation Solution
A method involving stamping and magnetic field alignment technology to transfer micro LEDs, where a polymer with ferromagnetic particles is used to simultaneously pattern and coat multiple elements, self-align, and electrically connect them to electrodes, allowing for efficient transfer and high-resolution integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pick-and-place transferring process is used to arrange millions of LED elements for high-resolution displays, then the display resolution can be achieved, but the mechanical precision requirements become excessively high and the process becomes inefficient
Solution Approach 1:
The patent merges the transfer process with the bonding process by using a stamping structure that simultaneously transfers multiple LED elements to the substrate and bonds them through a polymer layer in a single operation, eliminating the need for separate pick-and-place operations for each element
Solution Approach 2:
The patent replaces the mechanical pick-and-place system with a stamping mechanism that uses a polymer layer to transfer and bond LED elements, substituting complex mechanical positioning with a simpler stamping and curing process
2Manufacturing precision
If the size and spacing of individual electronic elements are reduced for higher resolution, then the display quality improves, but the mechanical precision requirements exceed the capabilities of conventional pick-and-place machines
Solution Approach 1:
The patent replaces the mechanical positioning system with a polymer-based transfer system where LED elements are transferred and positioned through the stamping mechanism, eliminating the need for high-precision mechanical positioning of individual micro elements
Solution Approach 2:
The patent introduces a polymer layer as an intermediary medium that facilitates the transfer and bonding of micro LED elements, allowing precise positioning without requiring the transfer machine to achieve extremely high mechanical precision
3Ease of manufacture
If conventional transfer methods are used, then individual elements can be transferred, but the process becomes increasingly unproductive and inefficient for large-area high-resolution displays
Solution Approach 1:
The patent combines multiple transfer operations into a single stamping action that transfers arrays of LED elements simultaneously, maintaining process simplicity while dramatically increasing productivity through parallel processing
Solution Approach 2:
The patent creates a universal transfer stamping system that can handle arrays of LED elements of various sizes and configurations, making the process equally simple and productive for different display resolutions and areas
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 method enables efficient transfer of micro LEDs across various sizes and resolutions, preventing electrical shorts and facilitating high-resolution displays, including augmented reality, virtual reality, and flexible displays, by using a polymer with ferromagnetic particles that align under a magnetic field for precise electrical connections.
Implementation Method 1
arranging the ferromagnetic particles in the polymer to electrically connect the electronic element array and the electrode by forming a magnetic field between the first substance and the third substrate
Data Source
AI summary
The present disclosure provides a method of transferring an electronic element using a stamping and magnetic field alignment technology and an electronic device including an electronic element transferred using the method. In the present disclosure, a polymer may be simultaneously coated on a plurality of electronic elements using the stamping process, and the polymer may be actively coated on the electronic elements without restrictions on process parameters such as size and spacing of the electronic elements. Moreover, the self-aligned ferromagnetic particles have an anisotropic current flow through which current flows only in the aligned direction. Therefore, the current may flow only vertically between the electronic element and the electrode, and there is no electrical short circuit between a peripheral LED element and the electrode.