Masked Light Distribution for Batch Soldering Mixed-Color LED Chips

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Solution Overview

Problem

The existing soldering processes for LED display screens are inefficient and prone to damaging red-light chips due to inconsistent laser power requirements for different colored chips during batch soldering.

Innovation Solution

A soldering apparatus with a mask having light-shielding and light-transmissive portions of varying transmittance allows for controlled light power distribution, enabling batch soldering of LED chips while preventing damage by aligning each chip with specific light-transmissive sub-portions corresponding to their power needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If chips are soldered one by one in the related art, then the soldering process can be completed with simple equipment, but the soldering efficiency is relatively low

Engineering Contradiction:
Improvesoldering efficiencyVSAvoidequipment complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent divides the soldering process into multiple parallel channels by using a mask with multiple light-transmissive portions. Each portion corresponds to a specific chip position, allowing simultaneous soldering of multiple chips through segmented light paths from a single laser source, thereby improving productivity without requiring proportionally more complex equipment

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent combines multiple soldering operations into a single batch process by integrating a mask that guides light to multiple chip positions simultaneously. This merging of parallel soldering tasks into one coordinated operation significantly increases throughput while keeping the laser source and control system unified rather than requiring separate lasers for each chip

Inventive Principle:
Principle #5Merging (Combining)

2Reliability

If laser output power is continuously adjusted for different colored chips, then the soldering quality can be optimized for each chip type, but the adjustment speed is insufficient and red-light chips may be damaged

Engineering Contradiction:
Improvechip soldering qualityVSAvoidpower adjustment speed
Core Design Contradiction:
ReliabilityVSSpeed

Solution Approach 1:

The patent applies local quality by assigning different light transmittance characteristics to different portions of the mask corresponding to different chip positions. Each light-transmissive portion is designed with specific transmittance properties tailored to the power requirements of chips at those positions, allowing optimized soldering quality for each chip type without requiring dynamic power adjustment during the batch soldering process

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent performs preliminary action by pre-configuring the mask with appropriate light transmittance properties for different chip positions before the soldering process begins. This advance preparation eliminates the need for real-time power adjustments during batch soldering, ensuring that each chip receives the correct power level from the start and preventing damage to red-light chips while maintaining high processing speed

Inventive Principle:
Principle #10Preliminary action

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 significantly enhances soldering efficiency and prevents chip damage by ensuring consistent and appropriate light power application during batch soldering of LED chips, improving production efficiency in LED display screen manufacturing.

Implementation Method 1

a light source configured to supply light radiation required for soldering

Methodology Applied
Scientific EffectLight radiation: Light

Implementation Method 2

including a light-shielding portion and multiple light-transmissive portions

Methodology Applied
Scientific EffectLight shielding: Absorption (EM radiation)

Data Source

PatentUS20240293893A1Soldering apparatus and soldering method using same
Publication Date: 2024.09.05 HCP TECH CO LTD
  • US20240293893A1 patent drawing
  • US20240293893A1 patent drawing

AI summary

A soldering apparatus and a soldering method using the same are provided. The soldering apparatus includes a light source configured to supply light radiation required for soldering; and a mask disposed on the light path of the light source and including a light-shielding portion and multiple light-transmissive portions. The multiple light-transmissive portions are spaced apart by the light-shielding portion and are configured for the light radiation to pass through. The mask has different transmittances so that the magnitude of the light power irradiated on a substrate can be controlled. Therefore, devices can not only be soldered in batches but also be prevented from being damaged caused by inconsistent requirements on light powers.