Light-Emitting Module Guiding Structure for LED Sorting Alignment
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Solution Overview
Problem
The manufacturing process of small-sized RGB LEDs faces challenges in efficiently sorting and identifying the direction of LED packaging products, particularly due to the limitations of existing methods such as vibration-based sorting and imaging equipment, which reduce efficiency and require additional alignment steps.
Innovation Solution
A light-emitting module with a guiding structure formed between conductive pads, allowing for directional sorting by engaging with a sorting structure on a track, eliminating the need for image sensors and enhancing sorting efficiency by ensuring proper alignment and integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vibration-based sorting is used for small-sized LEDs, then sorting can be performed, but sorting efficiency is reduced and difficulties increase as LED size decreases
Solution Approach 1:
The patent replaces vibration-based mechanical sorting with an imaging-based optical sorting system. The sorting machine uses imaging equipment to capture images of LED packaging products and identifies their directions through image processing, eliminating the inefficiencies of vibration-based methods for small-sized LEDs.
Solution Approach 2:
The patent introduces a blue film as an intermediary element to assist in the sorting process. The blue film is used in conjunction with the imaging system to enhance the visibility and identification of LED packaging product directions, thereby improving sorting accuracy and efficiency.
2Measurement precision
If imaging equipment is used to identify LED directions, then identification can be performed, but additional alignment work is required and packaging efficiency is reduced
Solution Approach 1:
The patent performs preliminary alignment by designing the LED packaging product structure with specific geometric features (such as rectangular shapes with defined corners) that automatically orient the products during the imaging process. This preliminary structural design eliminates the need for additional active alignment steps, thereby maintaining high packaging efficiency while achieving accurate direction identification.
3Manufacturing precision
If small-sized RGB LEDs are used to achieve high pixel density, then favorable resolution is delivered, but manufacturing challenges increase
Solution Approach 1:
The patent replaces complex mechanical handling and sorting methods with an imaging-based system that can accurately identify and sort small-sized LEDs without requiring complex mechanical adjustments. This substitution simplifies the manufacturing process while maintaining the ability to handle high pixel density requirements.
Data Source
AI summary
A light-emitting module includes a plurality of light-emitting elements, a plurality of conductive pads, and a package layer. Each of the light-emitting elements has a light-emitting surface and a back surface opposite to the light-emitting surface. The conducive pads are disposed above the back surfaces of the light-emitting elements. The package layer is disposed around the conducive pads, and has a guiding structure which is formed between two adjacent ones of the conducive pads and which extends in a direction orthogonal to a thickness direction of the package layer so as to extend across the package layer. A display device including the light-emitting module, and a method for sorting the light-emitting modules are also provided.