Optical Beam Offset Compensation for Precise Component Transfer
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Solution Overview
Problem
Laser-assisted transfer processes face positional errors due to misalignment between discrete components and target substrates, leading to placement errors during the transfer of ultra-thin and ultra-small components like LEDs, which affects precision and throughput.
Innovation Solution
The use of a Bingham fluid coating on the substrate, combined with a dynamic release structure and laser-assisted transfer, allows for precise alignment and placement of discrete components by adjusting the beam pattern offset to compensate for alignment errors, and the Bingham fluid prevents post-transfer movement and floating of components, ensuring accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser-assisted transfer process is used for assembling discrete components, then productivity is improved through high-throughput assembly, but manufacturing precision deteriorates due to positional errors and placement errors during transfer
Solution Approach 1:
The Bingham fluid coating is applied to the substrate before the transfer process, creating a pre-positioned receiving structure that will capture and hold the discrete component at the correct location during transfer
Solution Approach 2:
The patent utilizes the unique rheological parameters of Bingham fluid (yield stress and plastic viscosity) to create a coating that remains stable during transfer but allows precise component placement, changing the physical state characteristics of the receiving medium
2Manufacturing precision
If alignment adjustment is made to improve manufacturing precision, then component placement precision is improved, but device complexity increases due to additional optical system adjustments
Solution Approach 1:
The Bingham fluid coating itself provides the alignment and positioning function through its rheological properties, eliminating the need for complex external alignment mechanisms and making the system self-aligning
Solution Approach 2:
The Bingham fluid coating acts as an intermediary medium between the laser transfer system and the substrate, absorbing alignment errors and providing a tolerant interface that simplifies the overall system requirements
3Ease of operation
If dynamic release structure is used to enable component release, then ease of operation is improved for component transfer, but reliability deteriorates due to component floating and movement after transfer
Solution Approach 1:
The Bingham fluid exhibits a phase-like transition in its rheological behavior, maintaining stability during transfer then allowing precise component capture, effectively transitioning from a stable coating state to a component-receiving state
Solution Approach 2:
The system combines the dynamic release structure with the Bingham fluid coating to create a composite transfer and positioning system that leverages the complementary properties of both elements
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 approach enhances the precision and reliability of the transfer process, enabling high-throughput assembly of ultra-thin and ultra-small components with reduced placement errors and improved accuracy, facilitating their integration into electronic devices.
Implementation Method 1
a coating including a Bingham fluid disposed on a surface of the substrate
Implementation Method 2
irradiating the dynamic release structure disposed on a carrier, in which a discrete component is adhered to the dynamic release structure, the irradiating causing the discrete component to be released from the carrier
Implementation Method 3
The irradiating induces ablation of at least a portion of the dynamic release layer
Data Source
AI summary
A method includes determining an alignment error between a discrete component of a discrete component assembly mounted in a laser-assisted transfer system and a target position on a target substrate, the discrete component assembly including the discrete component adhered to a support by a dynamic release layer; based on the alignment error, determining a beam offset characteristic; and providing a signal indicative of the beam offset characteristic to an optical element of the laser-assisted transfer system, the optical element being configured to adjust a position of a beam pattern relative to the discrete component according to the beam offset characteristic.