Fluidic Self-Assembly Transfer of Micro Elements With Acoustic Feedback
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Solution Overview
Problem
Current technologies face challenges in accurately and efficiently transferring micro elements, such as LED chips, to specific positions on substrates due to the small size and complexity of these elements, which affects the commercialization and mass production of micro light-emitting diode (LED) displays.
Innovation Solution
An element transfer device utilizing fluidic self-assembly (FSA) with a cartridge containing element recesses and wave energy generators, controlled by a processor that uses machine learning algorithms to arrange micro elements with acoustic streaming signals, ensuring precise placement and arrangement of micro elements on substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional transfer methods are used for micro elements, then the process is simpler, but transfer accuracy deteriorates due to small size
Solution Approach 1:
The patent replaces conventional mechanical transfer methods with an acoustic field-based approach. Wave energy generators create acoustic waves in a fluid medium to manipulate micro element positions, eliminating the need for complex mechanical grippers or positioning mechanisms that cannot handle elements at 50 μm scale effectively.
Solution Approach 2:
The patent introduces a fluid medium as an intermediary between the wave energy generators and micro elements. The acoustic waves propagate through this fluid to exert forces on the micro elements, enabling precise control without direct mechanical contact. The fluid acts as a transmission medium for the acoustic energy.
2Productivity
If manual or conventional automated transfer is used, then equipment is simpler, but productivity deteriorates due to time-consuming processes
Solution Approach 1:
The patent enables continuous transfer operations by maintaining acoustic waves in the fluid medium throughout the transfer process. Multiple micro elements can be manipulated simultaneously and continuously rather than sequentially, as the acoustic field persists and can reposition elements on demand without interrupting the process flow.
Solution Approach 2:
The patent applies acoustic energy at intensities and durations sufficient to rapidly manipulate micro elements beyond what would be minimally required. This excessive action ensures quick, definitive positioning of elements, reducing the time each transfer operation takes and increasing overall manufacturing speed.
3Manufacturing precision
If precise positioning of micro elements is achieved, then transfer accuracy improves, but device complexity increases due to control requirements
Solution Approach 1:
The patent incorporates feedback mechanisms where the positions of micro elements are monitored (via imaging systems) and this information is fed back to the control system. The controller adjusts the acoustic wave parameters in real-time based on actual element positions, enabling closed-loop control that achieves high precision without requiring overly complex open-loop positioning mechanisms.
Solution Approach 2:
The patent uses dynamic control of acoustic wave parameters (frequency, amplitude, phase) to achieve precise positioning. Rather than static mechanical positioning, the system dynamically adjusts acoustic field characteristics to manipulate element positions, allowing adaptive and flexible control that simplifies the overall system architecture.
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 accurate and efficient transfer of micro elements onto substrates, improving the manufacturing speed and reducing defects in large display panels, thereby reducing production time and costs while enhancing transfer accuracy.
Implementation Method 1
at least one wave energy generator configured to supply wave energy having a certain frequency to the cartridge
Implementation Method 2
a vector field representing movement of the plurality of micro elements according to an output frequency of the at least one wave energy generator
Data Source
AI summary
An element transfer device is provided. The element transfer device includes a cartridge including a plurality of element recesses each having a shape corresponding to a shape of a micro element, at least one wave energy generator configured to supply wave energy to the cartridge, a camera, and a processor. The processor is configured to primarily arrange a plurality of micro elements in the plurality of element recesses by supplying the wave energy to the cartridge accommodating the plurality of micro elements disposed in a fluid, obtain a first image by photographing the cartridge, and based on the first image, control a waveform and a frequency of the wave energy and control a secondary arrangement of disposing the micro elements in remaining element recesses in which the micro elements are not disposed.