Magnetic Transfer Device for Micro-LED Placement Accuracy
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Solution Overview
Problem
The challenge lies in efficiently transferring a large number of small-sized light emitting elements, such as LEDs, to a target substrate due to their miniaturization, which complicates accurate and damage-free placement.
Innovation Solution
A transfer device comprising a non-magnetic plate with through holes and magnetic probes, where the magnetic plate generates a magnetic field to attract and collect light emitting elements, ensuring they are securely held without falling into the holes, and grooves between holes reduce magnetic field interference for precise placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If light emitting elements are miniaturized to increase quantity on target substrate, then productivity is improved, but manufacturing precision deteriorates due to difficulty in accurate placement
Solution Approach 1:
The invention divides the transfer device into multiple through-holes arranged in specific patterns, with each hole responsible for holding and transferring individual light emitting elements. This segmentation allows simultaneous handling of multiple elements while maintaining precise control over each element's position during transfer.
Solution Approach 2:
The invention introduces a magnetic field as an intermediary force between the transfer device and light emitting elements. The magnetic field enables non-contact holding and manipulation of the elements, eliminating mechanical contact that could cause displacement or damage, thereby maintaining high placement accuracy while transferring large quantities of elements.
2Ease of operation
If magnetic probes are used to attract light emitting elements, then ease of operation is improved, but object-generated harmful factors worsen due to magnetic field interference between adjacent elements
Solution Approach 1:
The invention creates localized magnetic fields at each through-hole position rather than a uniform magnetic field across the entire device. Each magnetic probe generates a confined magnetic field that attracts light emitting elements to its specific location, minimizing magnetic field overlap and interference between adjacent elements while maintaining ease of operation.
Solution Approach 2:
The magnetic field generation is segmented into multiple independent probes positioned at specific locations corresponding to through-holes. This segmentation of the magnetic field source reduces mutual interference between adjacent magnetic fields while collectively enabling easy collection and transfer of multiple light emitting elements.
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
Enables the efficient collection and accurate transfer of a large quantity of light emitting elements, minimizing damage and deviations during the transfer process, thus improving the efficiency of transferring these elements to a target substrate.
Implementation Method 1
a magnetic plate 14 on the first surface 11a of the non-magnetic plate 11 and blocking the first opening 12a of each of the through holes 12, wherein the magnetic plate 14 generates a magnetic field so that each of the probes 13 is capable of magnetically attracting one light emitting element 20
Data Source
AI summary
A device for collecting and transferring light emitting elements of microscale size includes a non-magnetic plate, a plurality of magnetic probes, and a magnetic plate. The non-magnetic plate defines through holes. Each of the probes is fixed in one through holes. The magnetic plate is on a surface of the non-magnetic plate and closes one opening of each of the through holes. The magnetic plate generates a magnetic field, so that each of the probes magnetically attracts one light emitting element. A method for making the transfer device and a method for transferring light emitting elements using the transfer device are also disclosed.