Stamped Micro LED Transfer With Magnetic Vertical Interconnects
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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 as element size and spacing decrease.
Innovation Solution
A method using stamping and magnetic field alignment technology to transfer micro LEDs, where a polymer with ferromagnetic particles is coated on an electronic element array, aligned with an electrode using a magnetic field, and cured to electrically connect the elements, allowing for efficient transfer and high-resolution integration without mechanical precision constraints.
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 individual element placement precision can be maintained, but productivity decreases dramatically and the process becomes inefficient for large-area applications
Solution Approach 1:
The patent merges multiple individual transfer operations into a single batch transfer process. The stamp structure allows simultaneous transfer of multiple LED elements (e.g., 2x2 array or larger) from carrier to substrate in one operation, replacing the conventional sequential pick-and-place process. This merging of operations dramatically improves productivity while maintaining precision through the stamp's fixed geometric patterns.
Solution Approach 2:
The stamp is segmented into multiple transfer regions, each capable of holding and transferring individual LED elements or small arrays. This segmentation allows the stamp to handle complex patterns of varying sizes and configurations, enabling high-resolution displays to be assembled through repeated stamping operations rather than individual placement.
2Area of stationary object
If conventional transfer methods are used for large-area displays, then coverage area increases, but the number of transfer operations required increases proportionally, reducing overall efficiency
Solution Approach 1:
The stamp can be designed with large active areas containing multiple transfer regions, enabling simultaneous transfer of dozens or hundreds of LED elements in a single operation. This merging of multiple transfer operations into batch processing dramatically reduces the total number of operations required for large-area displays, proportionally decreasing process time while maintaining full area coverage.
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 allowing for high-resolution displays, including augmented reality, virtual reality, and flexible displays, by using self-aligned ferromagnetic particles for anisotropic current flow.
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 substance
Implementation Method 2
curing the polymer to fix the state of the arranged ferromagnetic particles
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.