Colloidal Crystal Layer for Micro LED Transfer Head Bulge Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current Micro LED transfer processes face challenges in detecting abnormal bulges on raised transfer heads, which can lead to irreversible deformation and failure, causing chip transfer issues due to the lack of effective detection methods.

Innovation Solution

A transfer device with a colloidal crystal layer on the bulge of the transfer head, utilizing the Bragg reflection effect to determine the normalcy of the bulge by analyzing the light colors reflected, preventing the continued use of defective transfer heads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a raised transfer head is used for Micro LED transfer, then chip transfer capability is improved, but the bulge is prone to deformation and abnormality under heat and pressure

Engineering Contradiction:

Improvechip transfer capabilityVSAvoidbulge stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by forming the colloidal crystal layer on the bulge surface before the actual chip transfer process. This pre-prepared optical detection layer enables real-time monitoring of bulge deformation during subsequent heating and pressing operations, allowing early detection of abnormalities before they lead to transfer failures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback through the optical detection system using colloidal crystal layer. The Bragg reflection color changes provide real-time feedback on bulge deformation state, enabling continuous monitoring and early warning of abnormality during the chip transfer process, thus improving reliability while maintaining productivity.

Inventive Principle:

Principle #23Feedback

2Device complexity

If traditional detection methods are used for transfer head bulges, then device complexity is reduced, but detection precision is insufficient to identify abnormal bulges

Engineering Contradiction:

Improvedetection system simplicityVSAvoidbulge abnormality detection precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent utilizes color changes principle through the colloidal crystal layer's Bragg reflection effect. Different bulge deformation states correspond to different reflected colors, providing a simple yet precise visual detection method. This approach achieves high detection precision without requiring complex instrumentation, as the abnormality can be identified through color observation.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The patent replaces complex mechanical measurement systems with an optical detection system based on colloidal crystal Bragg reflection. This substitution maintains device simplicity while dramatically improving detection precision, as the optical method can detect subtle bulge deformations that mechanical gauges might miss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If no detection mechanism is implemented, then manufacturing cost is reduced, but chip transfer failure rate increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidchip transfer success rate

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent applies self-service principle by making the transfer head itself provide detection functionality through the integrated colloidal crystal layer. The transfer head structure serves dual purposes: chip transfer and self-diagnosis of bulge abnormality. This eliminates the need for separate external detection equipment, keeping manufacturing costs low while improving transfer success rate through early abnormality detection.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent converts the potentially harmful effect of undetected bulge deformation into a beneficial detection mechanism. The colloidal crystal layer transforms subtle physical changes in the bulge into visible color changes, turning what would be a hidden defect into an easily observable signal, thereby preventing transfer failures without adding significant cost.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

Enables effective detection of abnormal bulges, preventing chip transfer failures and ensuring the quality of Micro LED transfer processes, thereby improving product yield and reducing costs.

Implementation Method 1

Based on the characteristics that a Bragg reflection effect of a colloidal crystal microsphere structure can present different light colors, whether the bulge is abnormal or not can be determined according to light reflected based on the Bragg reflection effect of the colloidal crystal layer on each bulge

Methodology Applied

Scientific EffectBragg reflection effect: Bragg Diffraction

Data Source

PatentUS20230005781A1Transfer Device, and Manufacturing Method, Detection Method and Detection Device Thereof

Publication Date: 2023.01.05 CHONGQING KONKA PHOTOELECTRIC TECH RES INST CO LTD

AI summary

A transfer device, and a manufacturing method, a detection method and a detection device of the transfer device are provided. The transfer device includes a transfer head. A colloidal crystal layer is formed on at least one bulge of the transfer head. Based on the characteristics that a Bragg reflection effect of a colloidal crystal microsphere structure can present different light colors, whether the bulge is abnormal or not is determined according to light reflected by the colloidal crystal layer on each bulge.