Magnetic LED Supply in Fluid Chambers for Uniform Self-Assembly

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Solution Overview

Problem

Current methods for supplying semiconductor light emitting diodes (LEDs) are manual, non-uniform, and time-consuming, leading to potential damage and inefficiencies in large-scale display manufacturing.

Innovation Solution

An apparatus and method for automatically supplying semiconductor LEDs using a tray, transfer unit with magnets, and a controller to manage magnetic forces, enabling uniform and efficient placement of LEDs in a fluid chamber for self-assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual supply method is used, then operation simplicity is maintained, but supply speed and uniformity deteriorate

Engineering Contradiction:

Improveoperation simplicityVSAvoidsupply speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The semiconductor light emitting diodes automatically find their own positions in the fluid chamber through self-assembly, eliminating the need for precise manual placement while maintaining supply uniformity and increasing throughput

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical supply with an automatic supply device that uses fluid dynamics and magnetic fields to transport and position the diodes, significantly increasing supply speed while maintaining ease of operation through automated control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If manual supply method is used, then device complexity is low, but supply uniformity and time consumption worsen

Engineering Contradiction:

Improvedevice complexityVSAvoidsupply uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The controller coordinates the tray movement, magnet positioning, and supply timing based on feedback from sensors and pre-programmed parameters, ensuring uniform supply intervals and positions across multiple assembly lines

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The supply device is segmented into independent functional modules (tray, magnet unit, supply unit, controller) that can be optimized separately, allowing complex uniform supply patterns to be achieved through coordinated simple components

Inventive Principle:

Principle #1Segmentation

3Productivity

If excessive supply amount or height is used, then supply speed is improved, but damage to semiconductor light emitting diodes increases

Engineering Contradiction:

Improvesupply speedVSAvoiddiode integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The supply device dynamically adjusts the supply rate and height based on real-time conditions and pre-set parameters, allowing high-speed supply while preventing damage through adaptive control of supply intensity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The device incorporates protective mechanisms that cushion the semiconductor diodes during supply, preventing damage before it occurs through controlled fluid flow and magnetic field support rather than direct mechanical contact

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Productivity

If multiple assembly lines are supplied simultaneously, then productivity is improved, but control complexity increases

Engineering Contradiction:

Improvemulti-line supply efficiencyVSAvoidcontrol complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The supply device is designed with universal functionality to supply multiple assembly lines simultaneously using the same basic mechanism, achieving high productivity without proportional increases in control complexity through parameter-based configuration rather than structural complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Facilitates rapid, uniform, and damage-free supply of LEDs to multiple assembly lines, enhancing manufacturing efficiency and yield.

Implementation Method 1

a transfer unit including a magnet and a magnet receiving part, which receives the magnet, to transfer the semiconductor light emitting diodes using magnetic force

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS12500212B2Semiconductor light-emitting element supply device and supply method

Publication Date: 2025.12.16 LG ELECTRONICS INC

AI summary

A semiconductor light-emitting element supply device according to an embodiment of the present invention supplies semiconductor light-emitting elements in a fluid chamber in which self-assembly occurs, the semdconductor light-emitting element supply device comprising: a tray disposed in the fluid chamber; a transfer unit which includes a magnet and a magnet accommodating part for accommodating the magnet and which transfers the semiconductor light-emitting elements by using magnetic force; a supply unit disposed above the tray to supply the transferred semiconductor light-emitting elements to the tray; and a control unit for controlling operations of the tray, the transfer unit and the supply unit, wherein the control unit controls the position of the magnet accommodated in the magnet accommodating part so that the semiconductor light-emitting elements are adhered on one surface of the magnet accommodating part or the adhered semiconductor light-emittng elements are separated from the one surface of the magnet accommodating part.