Fluid Nozzle Module for Selective Removal of Misassembled Micro-LEDs
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Solution Overview
Problem
Current methods for removing mis-assembled semiconductor LEDs in a fluid assembly environment, such as those used in large-area display devices, face challenges due to the micro-level size and complexity of the components, leading to inefficiencies and low yield in the transfer process.
Innovation Solution
A removal module equipped with a fluid control system that includes a heating element or piezoelectric element to precisely control the fluid flow and a filtration system, allowing for the selective removal of mis-assembled LEDs by spraying a fluid to specific sites on the assembly board, thereby simplifying the structure and enhancing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If self-assembly technology is used for transferring semiconductor LEDs, then large-area display manufacturing is enabled, but mis-assembly of micro-level LEDs occurs
Solution Approach 1:
The invention segments the assembly board into multiple regions, with each region containing multiple nozzles that can independently spray fluid. This allows selective removal of mis-assembled LEDs from specific locations without affecting other areas, thereby maintaining high assembly precision across large display areas.
Solution Approach 2:
The invention applies local quality by enabling different regions of the assembly board to have different fluid spraying characteristics. Each nozzle can be independently controlled to spray fluid with specific pressure and flow rate tailored to the local requirements, allowing precise removal of mis-assembled LEDs while preserving correctly assembled ones.
2Manufacturing precision
If fluid spraying is used to remove mis-assembled LEDs, then selective removal is achieved, but control of fluid flow becomes complex
Solution Approach 1:
The invention incorporates a fluid reservoir that automatically supplies fluid to multiple nozzles, eliminating the need for separate fluid supply lines for each nozzle. The system self-regulates fluid distribution, reducing control complexity while maintaining precise fluid delivery to each nozzle for selective LED removal.
Solution Approach 2:
The invention uses a universal fluid control mechanism that serves all nozzles simultaneously. A single fluid supply system with centralized pressure control can manage multiple nozzles across different regions, simplifying the control architecture while enabling precise fluid delivery to any selected nozzle for targeted LED removal.
3Manufacturing precision
If heating element is used to control fluid, then fluid flow is precisely regulated, but energy consumption increases
Solution Approach 1:
The invention uses periodic heating cycles rather than continuous heating to control fluid flow. The heating element is activated only when fluid flow adjustment is needed, and the thermal mass of the fluid system maintains flow control between heating cycles. This periodic action reduces energy consumption while preserving precise fluid flow regulation capability.
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 enables the precise and efficient removal of mis-assembled semiconductor LEDs, improving the yield and accuracy of the assembly process by using a fluid-based system that can target and remove mis-assembled LEDs of several to tens of micrometers in size, thus addressing the limitations of existing technologies.
Implementation Method 1
the fluid control part may be a heating element configured to heat the inner space
Implementation Method 2
the fluid control part may include a piezoelectric element configured to apply vibration to the inner space according to an application of a pulse
Data Source
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AI summary
A removal module for removing a mis-assembled semiconductor light emitting diode includes a housing having an inner space formed by an upper plate having a nozzle hole and a lower plate spaced apart from the upper plate; a fluid supply part configured to supply a fluid outside the housing to the inner space; and a fluid control part configured to control spray of the fluid supplied to the inner space through the nozzle hole by adjusting a pressure of the inner space.