Collimator Assembly Alignment with LED Arrays
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Solution Overview
Problem
Current methods for aligning collimating lenses with light emitting diodes (LEDs) in display systems lack precision, leading to inefficiencies in light transmission and image quality, particularly in micro-LED based displays used in augmented and virtual reality applications.
Innovation Solution
A method involving lithography to form contact pads and features on a backplane, followed by bonding LEDs to these pads and aligning lenses using fusible material balls or protrusions, ensuring high precision alignment of lenses with LEDs for improved light collimation and image projection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment methods are used for collimating lenses with LEDs, then the alignment process is simple, but the alignment precision is insufficient leading to poor light transmission and image quality
Solution Approach 1:
Alignment features (protrusions or recesses) are formed on both the LED array substrate and collimator assembly during the manufacturing process before final assembly. This preliminary formation of alignment features ensures that when the assemblies are coupled together, the lenses align precisely with the LED emitters without requiring complex post-assembly adjustment procedures
Solution Approach 2:
Alignment features act as intermediary elements between the LED array substrate and the collimator assembly. These features (protrusions fitting into recesses or vice versa) serve as mechanical mediators that enforce precise geometric alignment during assembly, eliminating the need for complex alignment machinery or procedures
2Manufacturing precision
If alignment features are formed on contact pads, then alignment accuracy is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The alignment features are merged with the contact pad structures during the lithography and etching processes. By forming alignment features on the same substrate that contains the contact pads, the patent combines multiple functions (electrical connection and mechanical alignment) into a single integrated structure, reducing the need for separate alignment components and simplifying the overall manufacturing process
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 alignment accuracy of collimating lenses with LEDs, resulting in improved light transmission and image quality in micro-LED displays, particularly in augmented and virtual reality systems, by ensuring precise alignment and secure bonding.
Implementation Method 1
The first plurality of features may be balls including a fusible material, and the second plurality of features may be recesses in the collimator assembly
Data Source
AI summary
Disclosed herein are techniques for aligning a collimator assembly with an array of LEDs and apparatuses formed using the disclosed techniques. According to certain embodiments, a display projector includes a display device and a collimator assembly. The display device includes a backplane including a first plurality of features. The display device further includes a plurality of dies. Each die of the plurality of dies comprises a plurality of light emitting diodes and is bonded to the backplane. The collimator assembly includes a plurality of lenses and a second plurality of features. The collimator assembly is attached to the display device through coupling the first plurality of features with the second plurality of features such that the plurality of dies are aligned with the plurality of lenses.