Light-Emitting Element Transfer via Vacuum Positioning
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Solution Overview
Problem
Current testing systems for light-emitting elements face challenges in accurately testing chip-level devices due to complexity and increased costs, often resulting in misalignment between the light-emitting facet and optical sensors, which compromises testing accuracy.
Innovation Solution
A method involving a supporting stage with vacuum holes to transfer and position light-emitting elements, and probing with a direction perpendicular to the light-emitting surface to minimize misalignment and enhance testing accuracy, using a transferring component to place the element at a predetermined distance from vacuum holes and employing an optical sensor to detect emitted light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the light-emitting element is tested before packaging, then the testing accuracy may be compromised due to complexity, but the testing can be performed on chip-level elements
Solution Approach 1:
The testing system is segmented into distinct functional modules: a transferring component with vacuum holes for positioning, a supporting stage for stable placement, and separate probing components. This modular segmentation simplifies each individual component while maintaining overall testing accuracy, avoiding the complexity of integrated monolithic testing systems.
Solution Approach 2:
The vacuum holes act as an intermediary mechanism between the transferring component and the light-emitting element. By using vacuum suction through these holes, the system achieves precise positioning without complex mechanical clamping or alignment mechanisms, thereby maintaining testing accuracy while reducing system complexity.
2Productivity
If the light-emitting element is positioned close to vacuum holes for effective suction, then the transfer efficiency improves, but the misalignment between light-emitting facet and optical sensor increases
Solution Approach 1:
The vacuum holes are strategically positioned at specific locations on the transferring component where they provide effective suction without interfering with the optical alignment. The local geometry and distribution of vacuum holes are optimized to create stable positioning forces while maintaining the light-emitting facet's alignment with the optical sensor, thus achieving both transfer efficiency and measurement precision.
Solution Approach 2:
The system addresses the alignment issue by operating in multiple dimensions: the vacuum holes provide positioning in the vertical (Z) dimension through suction, while the transferring component maintains horizontal (X-Y) alignment through its geometric design. This multi-dimensional approach allows effective suction without compromising the alignment between the light-emitting facet and optical sensor.
3Ease of operation
If the probing direction is parallel to the light-emitting surface normal, then the alignment is easier, but the misalignment between probe and light-emitting facet occurs
Solution Approach 1:
The probing system employs an asymmetric probing direction that is angled relative to the light-emitting surface normal. This asymmetric approach allows the probe to access the light-emitting facet from an optimized angle, improving probing accuracy by reducing misalignment while maintaining ease of operation through the supporting stage's positioning capabilities.
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
This approach reduces the likelihood of misalignment and damage during testing, improving the accuracy and efficiency of light-emitting element testing while reducing costs by ensuring precise alignment and effective vacuum suction.
Implementation Method 1
vacuuming the at least one vacuum hole to attract the light-emitting element
Data Source
AI summary
A method of transferring a light-emitting element in a testing system includes transferring the light-emitting element to a predetermined position by a transferring component, and vacuuming the at least one vacuum hole to attract the light-emitting element. The predetermined position is spaced apart a distance from at least one vacuum hole, and the distance is greater than half of a width of the light-emitting element.