Light-Emitting Device Bonding Alignment Mark Formation
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Solution Overview
Problem
Current methods for producing small-size light-emitting devices are inefficient due to the lack of a streamlined process for bonding and aligning light-emitting elements with light transmission members, which complicates the formation of contact members and increases production time.
Innovation Solution
A method involving the simultaneous bonding of light-emitting elements to a plate-shaped light transmission member in a two-dimensional array, followed by image capture and alignment mark formation to determine positional offsets, allowing for precise positioning of contact members without individual image recognition for each element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual image recognition and alignment is performed for each light-emitting element, then positioning precision is improved, but production time increases
Solution Approach 1:
The patent merges multiple individual alignment operations into a single group alignment operation. By capturing an image of the entire array of light-emitting elements simultaneously and forming alignment marks based on the collective positions, the system achieves positioning precision comparable to individual alignment while drastically reducing production time through parallel processing of multiple elements.
Solution Approach 2:
The patent performs preliminary bonding of multiple light-emitting elements to the light transmission member in a two-dimensional array before performing alignment. This preliminary arrangement allows subsequent image capture and alignment mark formation to be performed on the entire group at once, rather than requiring sequential individual alignment operations.
2Productivity
If multiple light-emitting elements are bonded simultaneously in a two-dimensional array, then productivity is improved, but alignment complexity increases
Solution Approach 1:
The patent creates alignment marks on the light transmission member that serve as universal reference points for the entire array of light-emitting elements. These alignment marks enable subsequent positioning operations (contact member formation, cutting, etc.) to be performed on all elements simultaneously using a single reference system, rather than requiring separate alignment procedures for each element.
Solution Approach 2:
The alignment marks act as an intermediary between the light-emitting elements and the positioning system. Instead of directly measuring or aligning each individual element, the system uses the alignment marks as intermediate reference points that simplify the positioning process for the entire array.
3Ease of manufacture
If alignment marks are formed after bonding, then manufacturing flexibility is improved, but measurement precision requirements increase
Solution Approach 1:
The system uses the light-emitting elements themselves to define the alignment marks. By capturing an image of the bonded elements and determining alignment mark positions based on the element positions in the image, the system makes the elements self-referential for alignment purposes, eliminating the need for separate pre-defined alignment features.
Data Source
AI summary
A method for producing a light-emitting device includes: bonding a plurality of light-emitting elements to a plate-shaped light transmission member all at once with the plurality of light-emitting elements being arranged in a two-dimensional array extending in a first direction and a second direction; capturing an image of the plurality of light-emitting elements bonded to the light transmission member, and forming an alignment mark on the light transmission member based on positions in the image of the plurality of light-emitting elements; and after the forming of the alignment mark, forming a contact member in contact with a corresponding one of the plurality of light-emitting elements with the contact member being positioned with respect to the plurality of light-emitting elements by using the alignment mark.