Method for transferring light emitting elements, display panel, method for making display panel, and substrate

Patent metadata

Field	Value
Publication number	US-11114473-B2
Application number	US-201916681954-A
Country	US
Kind code	B2
Filing date	Nov 13, 2019
Priority date	Jul 5, 2019
Publication date	Sep 7, 2021
Grant date	Sep 7, 2021

Abstract

A method for transferring light emitting elements precisely during manufacture of display panels includes providing light emitting elements; providing a first electromagnetic plate defining magnetic adsorption positions; providing a receiving substrate defining receiving areas; providing a second electromagnetic plate; energizing the first electromagnetic plate to magnetically adsorb one light emitting element at one adsorption position; providing a second electromagnetic plate; and transferring the light emitting elements to one receiving area of the receiving substrate.

First claim

What is claimed is:

1. A method for transferring light emitting elements, comprising:
providing a plurality of light emitting elements, wherein a first magnetic material layer is on an end of each of the plurality of light emitting elements;
providing a first electromagnetic plate, wherein the first electromagnetic plate defines a plurality of adsorption positions, each of the plurality of adsorption positions is capable of magnetically attracting one light emitting element on being energized;
providing a receiving substrate, wherein providing the receiving substrate comprises providing a base layer, forming a second magnetic material layer on a side of the base layer, and forming a bonding layer on a side of the second magnetic material layer away from the base layer, wherein the bonding layer defines a plurality of receiving areas, each of the plurality of receiving areas is configured for receiving one of the plurality of light emitting elements;
energizing the first electromagnetic plate to magnetically adsorb one of the plurality of light emitting elements at each of the plurality of adsorption positions, wherein a surface of the first electromagnetic plate on which the plurality of light emitting elements are magnetically adsorbed is opposite to a surface of the receiving substrate defining the plurality of receiving areas, and the plurality of the light emitting elements are aligned one-to-one with the plurality of the receiving areas;
providing a second electromagnetic plate on a side of the base layer away from the second magnetic material layer; wherein the second electromagnetic plate has magnetic properties after being energized; and
powering on the second electromagnetic plate to form a magnetic field between the first magnetic material layer of each of the plurality of light emitting elements and the second magnetic material layer, and powering off the first electromagnetic plate so that each of the plurality of light emitting elements is detached from the first electromagnetic plate by the magnetic field and transferred to one corresponding receiving area of the receiving substrate.

2. The method according to claim 1 , wherein providing the receiving substrate further comprises patterning the second magnetic material layer to form a plurality of magnetic material units spaced apart from each other, and each of the plurality of magnetic material units is arranged to correspond to at least one of the plurality of receiving areas.

3. The method according to claim 1 , wherein forming the bonding layer further comprises forming a thin film transistor (TFT) array layer on a side of the second magnetic material layer away from the base layer and forming a pixel defining layer on a side of the TFT array layer away from the base layer, wherein the pixel defining layer defines a plurality of contact holes exposing the TFT array layer, each of the plurality of contact hole is defined as one of the plurality of receiving areas.

4. The method according to claim 3 , wherein forming the receiving substrate further comprises forming an insulating layer between the second magnetic material layer and the TFT array layer.

5. The method according to claim 1 , further comprising: forming an insulating nonmagnetic material layer on a surface of the first electromagnetic plate; and defining a plurality of through holes exposing the surface of the first electromagnetic plate in the insulating nonmagnetic material layer, wherein each of the plurality of through holes is defined as one of the plurality of adsorption positions.

6. A method for making a display panel, comprising:
providing a plurality of light emitting elements, wherein a first magnetic material layer is on an end of each of the plurality of light emitting elements;
providing a first electromagnetic plate, wherein the first electromagnetic plate defines a plurality of adsorption positions, each of the plurality of adsorption positions is capable of magnetically attracting one light emitting element on being energized;
providing a receiving substrate, wherein providing the receiving substrate comprises providing a base layer, forming an second magnetic material layer on a side of the base layer, and forming a bonding layer on a side of the second magnetic material layer away from the base layer, wherein, the bonding layer defines a plurality of receiving areas, each of the plurality of receiving areas is configured for receiving one of the plurality of light emitting elements;
energizing the first electromagnetic plate to magnetically adsorb one of the plurality of light emitting elements at each of the plurality of adsorption positions, wherein a surface of the first electromagnetic plate on which the plurality of light emitting elements are magnetically adsorbed is opposite to a surface of the receiving substrate defining the plurality of receiving areas, and the plurality of the light emitting elements are aligned one-to-one with the plurality of the receiving areas;
providing a second electromagnetic plate on a side of the base layer away from the second magnetic material layer, wherein the second electromagnetic plate has magnetic properties after being energized; and
powering on the second electromagnetic plate to form a magnetic field between the first magnetic material layer of each of the plurality of light emitting elements and the second magnetic material layer, and powering off the first electromagnetic plate so that each of the plurality of light emitting elements is detached from the first electromagnetic plate by the magnetic field and transferred to one corresponding receiving area of the receiving substrate.

7. The method according to claim 6 , wherein providing the receiving substrate further comprises patterning the second magnetic material layer to form a plurality of magnetic material units spaced apart from each other, and each of the plurality of magnetic material units is arranged to correspond to at least one of the plurality of receiving areas.

8. The method according to claim 6 , wherein forming the bonding layer further comprises forming a thin film transistor (TFT) array layer on a side of the second magnetic material layer away from the base layer and forming a pixel defining layer on a side of the TFT array layer away from the base layer, wherein the pixel defining layer defines a plurality of contact holes exposing the TFT array layer, each of the plurality of contact hole is defined as one of the plurality of receiving areas.

9. The method according to claim 8 , wherein forming the receiving substrate further comprises forming an insulating layer between the second magnetic material layer and the TFT array layer.

10. The method according to claim 8 , wherein forming the TFT array layer comprises forming a plurality of thin film transistors (TFTs), each of the plurality of light emitting elements having a first electrode and a second electrode, the first electrode of each of the plurality of light emitting elements is electrically connected with one of the plurality of TFTs.

11. The method according to claim 10 , after each of the plurality of light emitting elements is detached from the first electromagnetic plate by the magnetic field and transferred to a corresponding receiving area of the receiving substrate, the method further comprising forming a planarization layer on a side of the pixel defining layer away from the base layer, and the planarization layer fills a gap between adjacent two of the plurality of light emitting elements and exposes the second electrode of each of the plurality of light emitting elements.

12. The method according to claim 11 , further comprising forming a common ele

Assignees

• Century Tech Shenzhen Corporation Limited

Inventors

• Chen Po-Liang
• Lin Yung-Fu

Classifications

• H10W90/00

  Package configurations · CPC title

• H10P72/70

  for supporting or gripping · CPC title

• H10P72/0446 Primary

  Apparatus for mounting on conductive members, e.g. leadframes or conductors on insulating substrates · CPC title

• H10D86/451

  characterised by the compositions or shapes of the interlayer dielectrics · CPC title

• H10D86/60

  wherein the TFTs are in active matrices · CPC title