LED Transfer System Using Relay Substrate for Simultaneous Multi-Color Processing
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Solution Overview
Problem
The existing LED transfer process is inefficient due to the need to sequentially transfer red, green, and blue LEDs from separate wafers onto a target substrate, increasing manufacturing time for display modules.
Innovation Solution
A light emitting diode (LED) transfer system that includes an alignment apparatus, a handling robot, a transfer stage, a substrate stage, and a laser, controlled by a processor to align and transfer LEDs in a zigzag pattern across multiple target substrates simultaneously, reducing transfer time and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If LEDs are sequentially transferred from separate wafers for each color (red, green, blue), then the transfer process can be completed with simple equipment, but the manufacturing time increases significantly
Solution Approach 1:
The patent segments the transfer process into two independent stages: first transferring all LEDs from growth wafers to a relay substrate, then transferring from the relay substrate to the target substrate. This segmentation allows parallel processing of different color LEDs during the first stage, eliminating the sequential bottleneck while maintaining equipment simplicity.
Solution Approach 2:
The patent introduces a relay substrate as an intermediary carrier between the growth wafers and the target substrate. This relay substrate serves as a temporary holding platform that enables batch transfer of multiple color LEDs simultaneously, then facilitates their organized transfer to the final target substrate, thereby reducing overall manufacturing time.
2Productivity
If multiple target substrates are processed simultaneously, then manufacturing efficiency improves, but the complexity of the transfer system increases
Solution Approach 1:
The system segments the multiple target substrates into two groups: those already fixed on the transfer stage and those yet to be fixed. This segmentation allows the handling robot to efficiently manage substrates in batches, processing multiple substrates simultaneously without requiring complex real-time coordination of all substrates at once.
Solution Approach 2:
The alignment apparatus performs preliminary alignment of multiple target substrates before the transfer process begins. This preliminary action ensures that all substrates are pre-positioned and aligned correctly, allowing the transfer system to proceed with high-speed batch transfers without requiring complex real-time alignment mechanisms during the transfer operation.
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 system significantly reduces the overall manufacturing time for display modules by allowing simultaneous transfer of LEDs across multiple substrates, improving the efficiency of the LED transfer process.
Implementation Method 1
a laser configured to emit a laser beam toward the plurality of LEDs of the relay substrate disposed on the substrate stage so that the plurality of LEDs are transferred from the relay substrate to the plurality of target substrates
Implementation Method 2
The plurality of pins may adsorb and affix the plurality of target substrates by vacuum suction
Implementation Method 3
The gripper may adsorb and affix the plurality of target substrates by vacuum suction
Data Source
AI summary
A light emitting diode (LED) transfer system includes an alignment apparatus configured to align a plurality of target substrates; a handling robot configured to transport the plurality of target substrates; a transfer stage configured to hold the plurality of target substrates and move the plurality of target substrates; a substrate stage configured to move a relay substrate having a plurality of LEDs with respect to the transfer stage while the plurality of LEDs are facing the transfer stage; a laser configured to emit a laser beam toward the plurality of LEDs of the relay substrate so that the plurality of LEDs are transferred from the relay substrate to the plurality of target substrates; and a processor configured to control the alignment apparatus, the handling robot, the transfer stage, the substrate stage, and the laser to transfer the plurality of LEDs of the relay substrate to the plurality of target substrates.