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author:

Wu, Xin (Wu, Xin.) [1] | Zhu, Xueqi (Zhu, Xueqi.) [2] | Wang, Shuaishuai (Wang, Shuaishuai.) [3] | Tang, Xuehuang (Tang, Xuehuang.) [4] | Lang, Taifu (Lang, Taifu.) [5] | Belyaev, Victor (Belyaev, Victor.) [6] | Abduev, Aslan (Abduev, Aslan.) [7] | Kazak, Alexander (Kazak, Alexander.) [8] | Lin, Chang (Lin, Chang.) [9] | Yan, Qun (Yan, Qun.) [10] | Sun, Jie (Sun, Jie.) [11] (Scholars:孙捷)

Indexed by:

SCIE

Abstract:

Micro Light Emitting Diode (Micro-LED) technology, characterized by exceptional brightness, low power consumption, fast response, and long lifespan, holds significant potential for next-generation displays, yet its commercialization hinges on resolving challenges in high-density interconnect fabrication, particularly micrometer-scale bump formation. Traditional fabrication approaches such as evaporation enable precise bump control but face scalability and cost limitations, while electroplating offers lower costs and higher throughput but suffers from substrate conductivity requirements and uneven current density distributions that compromise bump-height uniformity. Emerging alternatives include electroless plating, which achieves uniform metal deposition on non-conductive substrates through autocatalytic reactions albeit with slower deposition rates; ball mounting and dip soldering, which streamline processes via automated solder jetting or alloy immersion but struggle with bump miniaturization and low yield; and photosensitive conductive polymers that simplify fabrication via photolithography-patterned composites but lack validated long-term stability. Persistent challenges in achieving micrometer-scale uniformity, thermomechanical stability, and environmental compatibility underscore the need for integrated hybrid processes, eco-friendly manufacturing protocols, and novel material innovations to enable ultra-high-resolution and flexible Micro-LED implementations. This review systematically compares conventional and emerging methodologies, identifies critical technological bottlenecks, and proposes strategic guidelines for industrial-scale production of high-density Micro-LED displays.

Keyword:

ball mounting bump fabrication dip soldering electroless plating electroplating evaporation high-density interconnects Micro-LED photosensitive conductive polymers

Community:

  • [ 1 ] [Wu, Xin]Fuzhou Univ, Coll Phys & Informat Engn, Fuzhou 350100, Peoples R China
  • [ 2 ] [Zhu, Xueqi]Fuzhou Univ, Coll Phys & Informat Engn, Fuzhou 350100, Peoples R China
  • [ 3 ] [Wang, Shuaishuai]Fuzhou Univ, Coll Phys & Informat Engn, Fuzhou 350100, Peoples R China
  • [ 4 ] [Tang, Xuehuang]Fuzhou Univ, Coll Phys & Informat Engn, Fuzhou 350100, Peoples R China
  • [ 5 ] [Lang, Taifu]Fuzhou Univ, Coll Phys & Informat Engn, Fuzhou 350100, Peoples R China
  • [ 6 ] [Lin, Chang]Fuzhou Univ, Coll Phys & Informat Engn, Fuzhou 350100, Peoples R China
  • [ 7 ] [Yan, Qun]Fuzhou Univ, Coll Phys & Informat Engn, Fuzhou 350100, Peoples R China
  • [ 8 ] [Sun, Jie]Fuzhou Univ, Coll Phys & Informat Engn, Fuzhou 350100, Peoples R China
  • [ 9 ] [Wu, Xin]Fujian Sci & Technol Innovat Lab Optoelect Informa, Fuzhou 350108, Peoples R China
  • [ 10 ] [Zhu, Xueqi]Fujian Sci & Technol Innovat Lab Optoelect Informa, Fuzhou 350108, Peoples R China
  • [ 11 ] [Wang, Shuaishuai]Fujian Sci & Technol Innovat Lab Optoelect Informa, Fuzhou 350108, Peoples R China
  • [ 12 ] [Tang, Xuehuang]Fujian Sci & Technol Innovat Lab Optoelect Informa, Fuzhou 350108, Peoples R China
  • [ 13 ] [Lang, Taifu]Fujian Sci & Technol Innovat Lab Optoelect Informa, Fuzhou 350108, Peoples R China
  • [ 14 ] [Lin, Chang]Fujian Sci & Technol Innovat Lab Optoelect Informa, Fuzhou 350108, Peoples R China
  • [ 15 ] [Sun, Jie]Fujian Sci & Technol Innovat Lab Optoelect Informa, Fuzhou 350108, Peoples R China
  • [ 16 ] [Belyaev, Victor]State Univ Educ, Fac Phys & Math, Very Voloshinoi Str 24, Mytishchi 141014, Russia
  • [ 17 ] [Abduev, Aslan]State Univ Educ, Fac Phys & Math, Very Voloshinoi Str 24, Mytishchi 141014, Russia
  • [ 18 ] [Kazak, Alexander]State Univ Educ, Fac Phys & Math, Very Voloshinoi Str 24, Mytishchi 141014, Russia
  • [ 19 ] [Sun, Jie]Chalmers Univ Technol, Dept Microsci & Nanotechnol, S-41296 Gothenburg, Sweden

Reprint 's Address:

  • 孙捷

    [Sun, Jie]Fuzhou Univ, Coll Phys & Informat Engn, Fuzhou 350100, Peoples R China;;[Sun, Jie]Fujian Sci & Technol Innovat Lab Optoelect Informa, Fuzhou 350108, Peoples R China;;[Sun, Jie]Chalmers Univ Technol, Dept Microsci & Nanotechnol, S-41296 Gothenburg, Sweden

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Source :

MATERIALS

Year: 2025

Issue: 8

Volume: 18

3 . 1 0 0

JCR@2023

Cited Count:

WoS CC Cited Count:

SCOPUS Cited Count:

ESI Highly Cited Papers on the List: 0 Unfold All

WanFang Cited Count:

Chinese Cited Count:

30 Days PV: 0

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