Transfer Film Elongation Control for Precise LED Panel Alignment
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Solution Overview
Problem
Existing technologies face challenges in precisely and accurately arranging light-emitting diodes on display panels, particularly inorganic light-emitting diodes, during the fabrication process.
Innovation Solution
An apparatus and method involving a fixing frame, optical inspection member, and elongation processing member are used to control the elongation of a transfer film, ensuring that light-emitting elements are aligned accurately and positioned at desired distances on the display panel substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light-emitting diodes are transferred onto the substrate using existing apparatuses, then the display panel can be fabricated, but the light-emitting diodes cannot be arranged at desired distances precisely and accurately
Solution Approach 1:
A transfer film is introduced as an intermediary carrier to hold multiple light-emitting diodes during the transfer process. The transfer film allows precise positioning of LEDs relative to each other before transfer, and enables accurate distance control during transfer to the substrate, resolving the contradiction between fabrication capability and arrangement precision.
Solution Approach 2:
The patent replaces traditional mechanical transfer methods with an optical-based positioning system. Optical markers on the transfer film are detected by a sensor to determine the position of light-emitting diodes, enabling precise distance control and accurate arrangement that mechanical systems alone cannot achieve.
2Productivity
If light-emitting diodes are arranged on the substrate, then the display panel function is achieved, but the arrangement process is complex and time-consuming
Solution Approach 1:
Multiple light-emitting diodes are pre-arranged on the transfer film at desired distances and positions before the transfer process. This preliminary arrangement simplifies the overall fabrication process by enabling batch transfer of multiple LEDs in their final positions, improving productivity while reducing process complexity.
Solution Approach 2:
The transfer film acts as a template or copy that replicates the desired LED arrangement pattern. By creating the arrangement on the transfer film first and then transferring it to the substrate, the complex arrangement process is simplified into a replication operation, enhancing efficiency and reducing fabrication complexity.
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
Enables precise and efficient arrangement of light-emitting diodes, facilitating the formation of display panels with improved accuracy and consistency in element placement.
Implementation Method 1
an optical inspection member including a light source for irradiating light toward the transfer film and a light-receiving sensor along (or in) an optical path of the light source
Data Source
AI summary
An apparatus for fabricating a display panel includes: a fixing frame for fixing an outer circumference of a transfer film on which a plurality of light-emitting elements is arranged; an optical inspection member including a light source for irradiating light toward the transfer film and a light-receiving sensor in an optical path of the light source; and an elongation processing member for elongating a width of the transfer film toward an outer circumference thereof and for controlling a degree of elongation based on detection results by the optical inspection member. The light-emitting elements include first light-emitting elements and second light-emitting elements, and the second light-emitting elements include alignment keys on one side.