Magnetic Pick-Up Device for Micro-Device Transfer
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Solution Overview
Problem
The existing transfer methods for micro-devices, such as those used in LED display apparatus manufacturing, face challenges with insufficient manufacturing yield, inaccuracy, and difficulty in scaling up for mass production due to the limitations of elastic transfer heads with bumps.
Innovation Solution
A transfer method and apparatus utilizing a pick-up device with caves and a magnetic force to accurately position and transfer micro-devices, ensuring precise alignment and improved yield through the balance of magnetic and mechanical forces, allowing for efficient transfer to a receiving device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If elastic transfer head with bumps is used for micro-device transfer, then the transfer process can be implemented, but manufacturing yield is insufficient and accuracy is poor
Solution Approach 1:
The patent replaces the purely mechanical elastic transfer head with a hybrid system combining magnetic fields and mechanical caves. The magnetic device generates magnetic force to attract and position micro-devices precisely on the caves, eliminating the inaccuracy of purely mechanical bump-based transfer while maintaining the transfer capability.
Solution Approach 2:
The patent introduces magnetic force as an intermediary between the transfer head and micro-devices. The magnetic device acts as a mediator that enables precise positioning and stable attachment of micro-devices to the caves, resolving the contradiction between transfer feasibility and transfer accuracy.
2Productivity
If elastic transfer head with bumps is used, then transfer can be performed, but scaling up for mass production is difficult
Solution Approach 1:
The pick-up device with caves and magnetic device combination serves multiple functions: attracting micro-devices, positioning them accurately, holding them stable during transfer, and releasing them at the destination. This multi-functional design enables scalable mass production without proportionally increasing system complexity.
3Measurement precision
If magnetic force is applied to attract micro-devices, then positioning accuracy improves, but the system complexity increases
Solution Approach 1:
The patent merges the magnetic device with the pick-up device having caves into an integrated transfer system. The magnetic device and mechanical caves work together as a unified system, where the magnetic force provides positioning accuracy while the caves provide physical containment, achieving high precision without proportionally increasing overall system complexity.
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 solution enhances manufacturing yield and accuracy by ensuring precise alignment and efficient transfer of micro-devices, addressing the limitations of existing methods and enabling scalable mass production.
Implementation Method 1
a first magnetic force configured to attract a plurality of micro-devices to move toward the caves of the pick-up device
Data Source
AI summary
A pick-up device has a caves. A first magnetic force is capable of attracting micro-devices to move toward the caves of the pick-up device. The pick-up device is disposed on a pick-up roller, and the pick-up roller drives the caves of the pick-up device to move relative to the micro-devices. Given that the first magnetic force is provided, the pick-up device compresses the micro-devices, so that the micro-devices are fitted in place the micro-devices into the caves of the pick-up device, wherein a shape of the caves is the same as a shape of the micro-devices. The micro-devices are transferred from the caves of the pick-up device to a receiving device.