Magnetic Adsorption Device for Micro LED Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In the manufacturing process of micro LED display devices, existing electrostatic attraction methods for transferring LEDs to a substrate can damage the circuit due to static electricity, necessitating a more reliable and safe transfer method.
Innovation Solution
A magnetic adsorption device with magnetic units on a substrate, where each magnetic unit consists of a magnet and a cladding layer, generates a localized magnetic force to attract and hold LEDs, allowing for precise positioning and transfer without damaging the circuit, and can be adjusted for flexibility in use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrostatic attraction method is used to transfer LEDs, then LEDs can be held to transferring substrate, but static electricity may damage the circuit on the substrate
Solution Approach 1:
The patent replaces the electrostatic attraction method with a magnetic field-based adsorption system. Magnets are embedded in the transferring substrate to generate magnetic fields that attract and hold LED beads, eliminating the need for electrostatic charges that could damage sensitive circuits while maintaining effective transfer capability
Solution Approach 2:
The patent changes the physical parameter used for adsorption from electrical charge to magnetic field strength. By controlling magnetic field parameters (field intensity, distribution, and polarity), the system achieves reliable LED holding and release without the harmful effects of static electricity
2Reliability
If magnetic units are added to substrate to enable magnetic adsorption, then transfer safety improves, but device complexity increases
Solution Approach 1:
The patent embeds magnets within recesses or cavities of the transferring substrate, creating a nested structure where magnets are housed inside the substrate body. This integration minimizes the increase in device complexity while maintaining the magnetic adsorption functionality for safe LED transfer
Solution Approach 2:
The patent implements magnetic units only at specific locations where LED transfer is needed, rather than making the entire substrate magnetic. This localized approach maintains transfer safety while minimizing overall device complexity and material usage
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 magnetic adsorption device enables efficient and damage-free transfer of a large number of LEDs onto a substrate, enhancing manufacturing efficiency, particularly for small LEDs like mini and micro LEDs, by using localized magnetic forces that do not affect the entire substrate.
Implementation Method 1
Each of the plurality of magnetic units 12 generates a localized magnetic force to attract a predetermined target object 20
Data Source
AI summary
A device to attract and hold microscopic items such as micro LEDs magnetically rather than by static electricity includes a substrate and a plurality of magnetic units on a surface of the substrate. The magnetic units are spaced apart from each other and are constrained in the size and direction of their individual magnetic fields. Each of the magnetic units includes a magnet and a cladding layer partially covering the magnet. The cladding layer is made of a magnetic material. A side of the magnet away from the substrate is exposed from the cladding layer to attract and hold one micro LED.