Display Assembly Contaminant Separation for Micro-LED Transfer
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Solution Overview
Problem
The challenge is to effectively remove foreign substances from semiconductor light emitting devices before they are assembled on a display substrate, as these foreign substances can cause defects such as lighting defects, electrical short circuits, and reduced brightness.
Innovation Solution
A display manufacturing apparatus is designed with a foreign substance removal device that includes two modules: one for filtering non-magnetic foreign substances and another for filtering magnetic foreign substances. This apparatus ensures that semiconductor light emitting devices are free from foreign substances before assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If self-assembly method is used to transfer light emitting devices onto substrate, then transfer speed and accuracy are improved, but foreign substances cause defects such as lighting defects, electrical short circuits, and reduced brightness
Solution Approach 1:
The patent applies preliminary action by introducing a foreign substance removal process before the self-assembly transfer process. A removal unit is configured to remove foreign substances from light emitting devices prior to their transfer onto the substrate, preventing defects while maintaining the high-speed transfer benefits of the self-assembly method.
Solution Approach 2:
The patent applies the extraction principle by specifically targeting and removing foreign substances from the light emitting devices. The removal unit extracts contaminants including metallic, non-metallic, and fragmentary foreign substances from the devices before assembly, eliminating the source of defects without affecting the transfer process.
2Ease of manufacture
If foreign substances are present on light emitting devices, then assembly process is simplified, but defects occur including lighting defects, electrical short circuits, and reduced brightness
Solution Approach 1:
The patent applies preliminary action by implementing a foreign substance removal step before assembly. The removal unit is configured to clean light emitting devices of foreign substances prior to the assembly process, ensuring high-quality electrical connections and preventing defects while maintaining manufacturing efficiency.
3Reliability
If foreign substances are removed before assembly, then defect rate is reduced, but manufacturing process complexity increases
Solution Approach 1:
The patent applies universality by designing a removal unit that can handle multiple types of foreign substances (metallic, non-metallic, and fragmentary) with a single integrated structure. This multi-functional approach removes various contaminants effectively while avoiding the need for multiple separate removal processes, thus limiting the increase in manufacturing complexity.
4Loss of time
If foreign substances are not removed, then manufacturing time is reduced, but product quality deteriorates with lighting defects and electrical issues
Solution Approach 1:
The patent applies preliminary action by performing foreign substance removal in advance of the assembly process. The removal unit is configured to clean light emitting devices before they are transferred and assembled, ensuring high product quality with proper electrical connections and lighting performance while maintaining efficient manufacturing timing.
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
The solution prevents defects such as lighting defects, electrical short circuits, and reduced brightness by ensuring that semiconductor light emitting devices are free from foreign substances before assembly on the display substrate, thereby improving the electrical and optical properties of the display.
Implementation Method 1
a first separation unit that separates the non-magnetic foreign substance among the foreign substance of the plurality of semiconductor light emitting devices accommodated in the first bath from the magnetic foreign substance and the plurality of semiconductor light emitting devices
Implementation Method 2
a second separation unit that separates the magnetic foreign substance among the foreign substance of the plurality of semiconductor light emitting devices accommodated in the second bath from the plurality of semiconductor light emitting devices
Data Source
AI summary
A display manufacturing apparatus includes a foreign substance removal device and an assembly device. The foreign substance removal device removes foreign substances from a plurality of semiconductor light emitting devices. The assembly device assembles the plurality of removed semiconductor light emitting devices on a display substrate. The foreign substance includes magnetic foreign substance and non-magnetic foreign substance. The foreign substance removal device includes a first module for filtering non-magnetic foreign substance among the foreign substance of the plurality of semiconductor light emitting devices, and a second module for filtering magnetic foreign substance among the foreign substances of the plurality of semiconductor light emitting devices.