LED Transfer Head Rotation for Simultaneous Multi-Device Placement
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Solution Overview
Problem
Conventional light-emitting diode (LED) transfer processes have low productivity and long manufacturing times, limiting the efficiency of transferring LEDs from one substrate to another.
Innovation Solution
A light-emitting diode transfer apparatus and method that includes a stage, a moving portion, a second linear driving portion, and a head portion with pick-up portions, allowing for simultaneous transfer of multiple LEDs by linear motion and rotation, enabling efficient alignment and transfer under vacuum conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional LED transfer process is used, then manufacturing process is simple, but productivity is low and manufacturing time is long
Solution Approach 1:
The transfer apparatus is divided into multiple independent head portions, each capable of picking up and transferring LEDs separately. This segmentation allows parallel operation of multiple heads simultaneously, increasing overall transfer speed without complicating the basic transfer mechanism
Solution Approach 2:
The invention introduces rotational motion as an additional dimension to the linear transfer path. Head portions can rotate to access LEDs at different angular positions, enabling simultaneous picking up of multiple LEDs from different locations and transferring them to corresponding positions on the target substrate
2Productivity
If multiple LEDs are transferred simultaneously, then productivity increases, but device complexity increases
Solution Approach 1:
Each head portion is designed as a universal module that can pick up, hold, and transfer LEDs. The same head structure is replicated multiple times, allowing the system to handle different LED positions and orientations without requiring different transfer mechanisms for each LED
Solution Approach 2:
Multiple head portions are merged into a single integrated transfer apparatus that operates simultaneously. The control system merges the coordination of multiple heads, linear motion, and rotation into a unified operation that transfers multiple LEDs in parallel without requiring separate transfer mechanisms
3Manufacturing precision
If head portion rotates to pick up LEDs, then alignment precision improves, but device complexity increases
Solution Approach 1:
The head portion is designed with dynamic rotational capability that allows it to adjust its orientation during the transfer process. This dynamic adjustment enables precise alignment with LEDs at different positions and orientations on the substrate, achieving high placement accuracy while maintaining a relatively simple head structure through motion control rather than mechanical complexity
Data Source
AI summary
A light-emitting diode transfer includes: a stage; a moving portion disposed on the stage and which performs a linear motion on the stage; a linear driving portion disposed on the moving portion and which performs a linear motion on the moving portion; and a head portion rotatably disposed on the linear driving portion and which picks up a light-emitting diode.