Magnet Unit Layout for LED Chip Self-Assembly Alignment
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Solution Overview
Problem
The self-assembly of semiconductor light emitting devices for display pixels faces challenges in controlling the direction of semiconductor light emitting device chips, leading to reduced assembly rates and increased residual chips, which result in assembly defects and the need for additional chip collection processes.
Innovation Solution
A magnet unit with a magnet body and a magnet control unit around its circumference, including spacers and focusing units made of materials like ferrite, nickel, and cobalt alloys, is used to control the magnetic field distribution, allowing for improved alignment and positioning of semiconductor light emitting devices on the assembly substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the transfer speed of semiconductor light emitting devices is increased to improve assembly efficiency, then productivity is improved, but the transfer error rate increases and manufacturing precision deteriorates
Solution Approach 1:
The semiconductor light emitting device is designed to self-assemble on the display panel through magnetic field interaction. The device chip includes a magnetic layer that responds to the magnetic field from the display panel, enabling automatic positioning and assembly without manual intervention or complex external manipulation mechanisms, thus achieving high speed and high precision simultaneously
Solution Approach 2:
The traditional mechanical pick-and-place system is replaced with a magnetic field-based self-assembly mechanism. Instead of using mechanical arms and grippers that limit speed and precision, the invention uses magnetic field interaction between the magnetic layer on the device chip and the magnetic field source on the display panel to achieve rapid and accurate assembly
2Device complexity
If conventional self-assembly methods are used without direction control, then device complexity is reduced, but manufacturing precision deteriorates due to inability to control chip direction
Solution Approach 1:
The magnetic field distribution on the display panel is designed with local variations to provide directional information. Specific regions of the magnetic field have different strengths or orientations, enabling the semiconductor light emitting device to not only locate its assembly position but also orient itself correctly during self-assembly, achieving high precision without complex external control mechanisms
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 solution enhances the assembly rate by 2 to 3 times, reduces residual chips, and improves assembly efficiency by ensuring accurate placement and minimizing vertical magnetic field interference, thus preventing assembly defects and eliminating the need for separate chip collection.
Implementation Method 1
a magnet unit capable of controlling the direction of a semiconductor light emitting device for a display pixel
Implementation Method 2
the magnetic field forming unit approaches the assembly substrate through vertical and horizontal movement
Implementation Method 3
the semiconductor light emitting devices are adhered to the assembly surface by the magnetic field forming unit
Implementation Method 4
a step of moving a group of semiconductor light emitting device chips including magnetic materials by a large number of rotating magnet rods
Data Source
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AI summary
The embodiment relates to a magnet unit (710) of a semiconductor light emitting device for a display pixel and a self-assembly device using the same. A magnet unit (710) according to an embodiment includes a magnet body (702) and a magnet control unit (704) disposed around an outer circumference of the magnet body. The magnet control unit includes a first magnet focusing unit (704B) spaced apart from an outer circumference of the magnet body and a first spacer (704A) disposed between the magnet body (702) and the first magnet focusing unit (704B).