Alignment Tray for High-Precision Micro-LED Batch Placement
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Solution Overview
Problem
Current technologies for assembling micro-LED elements, such as mini-LEDs and micro-LEDs, face challenges in achieving high precision and throughput for mounting a large number of minute elements on a mounting board, particularly with alignment margins as tight as ±1.5 micrometers.
Innovation Solution
The development of an alignment-assisting tray with concave cells that store elements individually, aligned according to the layout on the mounting board, and a driving unit that realigns the elements within the tray to achieve precise alignment. This method includes a first transferring unit for transporting elements to the tray, a second transferring unit for picking up aligned elements, and a controlling circuit to manage the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional transferring apparatus (pick & place scheme) is used, then throughput can be maintained at 20,000 chips/hour, but alignment precision deteriorates to within a range of about 35 micrometers
Solution Approach 1:
The invention divides the transfer process into two distinct stages: a rough transfer stage using pick & place scheme to move elements to the alignment tray, and a precise alignment stage using the alignment tray with convex-ridge interfaces. This segmentation allows each stage to optimize for its specific function, resolving the contradiction between throughput (rough transfer) and precision (alignment)
Solution Approach 2:
The alignment tray serves as an intermediary device between the rough transfer apparatus and the final mounting position. It receives elements with low precision, performs high-precision alignment through convex-ridge interfacing, and then transfers the aligned elements to the mounting board, thus mediating between throughput and precision requirements
2Manufacturing precision
If alignment precision is improved to ±1.5 micrometers, then manufacturing precision is improved, but device complexity increases due to need for specialized alignment tray and control apparatus
Solution Approach 1:
The alignment tray enables self-alignment of elements through its convex-ridge interfaces that automatically guide elements into precise positions based on their geometric features, reducing the need for complex external alignment control systems and sensors
3Length of moving object
If minute elements with side length of about 15 micrometers are assembled, then product miniaturization is achieved, but alignment difficulty increases due to tight alignment margin of ±1.5 micrometers
Solution Approach 1:
The invention performs preliminary rough alignment by transferring elements to the alignment tray in an ordered array, establishing a preliminary position that is then refined through the convex-ridge alignment mechanism. This preliminary action reduces the difficulty of final precise alignment for minute elements
Data Source
AI summary
An alignment-control apparatus encompasses an alignment-assisting tray for aligning a plurality of elements in a batch with highly minute-and-precise configuration, a first transferring unit for collectively transporting the plurality of elements to the alignment-assisting tray, a driving unit for reallocating a convex-ridge of each of the elements toward an concave-ridge assigned to each of the concave cells defined in the alignment-assisting tray, and a second transferring unit for picking up the plurality of elements from the alignment-assisting tray and collectively transporting the plurality of elements.