Micro-Assembly Electrode Array for Multi-Object Position Control
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Solution Overview
Problem
Current techniques for micro- and nano-scale particle manipulation lack the precision and scalability to effectively control the movement and assembly of multiple micro- and nano-objects of varying shapes and sizes, particularly in industrial applications such as electronics assembly, due to limitations in electric field control and actuation mechanisms.
Innovation Solution
A system and method utilizing a high-speed camera, photo-transistor-controlled electrodes, and a video projector to create a dynamic potential energy landscape, enabling Model Predictive Control (MPC) optimization for precise movement and assembly of micro-objects by generating desired trajectories and electric potentials, allowing for simultaneous control of multiple objects with varying shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uncontrolled mechanical agitation is used for directed particle assembly, then the process is simple to implement, but the yield and precision are insufficient to achieve near 100% yield required for industrial applications
Solution Approach 1:
The patent replaces uncontrolled mechanical agitation with a controlled electric field-based manipulation system. Electrodes generate electric fields that exert dielectrophoretic forces on micro-objects, enabling precise control of particle movement and assembly while achieving near 100% yield required for industrial applications
Solution Approach 2:
The system dynamically adjusts electric field parameters (voltage, frequency, electrode configuration) to control the movement and assembly of micro-objects. By changing these parameters, the system can achieve both high precision positioning and high assembly yield, resolving the contradiction between control precision and productivity
2Manufacturing precision
If a one-step model predictive control approach with spiral-shaped electrodes is used, then micro-chiplet position control is achieved, but the number of simultaneously actuated electrodes is limited and applicability to larger particles is restricted
Solution Approach 1:
The patent employs an array of multiple independently controllable electrodes rather than a single spiral-shaped electrode. This segmentation allows different regions of the electrode array to be actuated simultaneously, increasing the number of particles that can be manipulated and enabling control of particles with various sizes and shapes by adjusting which electrodes are active
Solution Approach 2:
The system uses dynamic model predictive control that adapts to different particle characteristics. The control algorithm adjusts electrode actuation patterns in real-time based on particle position, size, and shape, enabling the same system to effectively manipulate particles across a wide range of dimensions while maintaining high positioning precision
3Measurement precision
If electrophoretic forces are used for particle manipulation with MHz high frequency signals, then single particle precision is achieved, but the technique is not suitable for assembling micro-objects slightly larger than those discussed and throughput is limited
Solution Approach 1:
The patent uses periodic alternating current signals at optimized frequencies to drive dielectrophoretic manipulation. By using multiple electrodes actuated in coordinated periodic patterns, the system achieves both single-particle precision and high throughput assembly, overcoming the limitation of previous single-electrode approaches that required MHz frequencies and limited throughput
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 approach enables accurate and scalable control of micro- and nano-objects, achieving high precision and throughput in assembling complex patterns and configurations, such as chiplet arrays, by dynamically adjusting electric potentials and trajectories, overcoming previous limitations in size and shape constraints.
Implementation Method 1
each of the electrodes controlled by a photo-transistor, the electrodes configured to induce a movement of the chiplets when the chiplets are suspended in a fluid proximate to the electrodes upon a generation of one or more electric potentials by one or more of the electrodes
Implementation Method 2
The video projector is controlled to project the one or more further images to the photo-transistors, wherein the photo-transistors control the electrodes to generate the electrode potentials in the control scheme based on the projected images
Data Source
AI summary
System and method that allow to jointly cause movement of multiple micro-and-nano-objects to desired positions are described. A high speed camera tracks the locations of the objects. An array of photo-transistor-controlled electrodes is used to generate a dynamic potential energy landscape for manipulating objects with both DEP and EP forces, and a video projector is used actuate the array. One or more computing devices are used to: process images captured by the camera to estimate positions of the objects; generate desired trajectories of the objects using an objective function; compare the desired chiplet positions with current positions and generate input signals to minimize the error between them; and map the control inputs to images that are projected on the array using a video project. The projected images activate or deactivate electrodes, as indicated by the control inputs.