Micro LED Element Alignment Using an Array Guide Member
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Solution Overview
Problem
The challenge in manufacturing micro LED display devices lies in accurately aligning and mounting numerous fine light-emitting elements with non-rotationally and non-linearly symmetric shapes onto a mounting substrate, as they are difficult to visually recognize and require high precision to conform to a pixel array, making existing methods inefficient.
Innovation Solution
A method involving an array guide member with opening portions of similar shape and slightly larger dimensions than the light-emitting elements, which are aligned and fitted using a vibration and swing mechanism to ensure precise posture and two-dimensional array alignment, allowing for efficient transfer and mounting onto the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light-emitting elements are mounted directly without alignment assistance, then mounting speed may be faster, but alignment precision deteriorates making it impossible to conform to pixel array requirements
Solution Approach 1:
A guide member is introduced as an intermediary component between the light-emitting elements and the mounting substrate. The guide member contains guide holes with shapes matching the light-emitting elements, enabling precise alignment through mechanical fitting while maintaining efficient batch mounting capability
Solution Approach 2:
The guide member is prepared in advance with pre-formed guide holes that correspond to the pixel array pattern. This preliminary preparation of alignment structures eliminates the need for time-consuming alignment operations during the actual mounting process
2Manufacturing precision
If traditional alignment methods are used, then some elements can be aligned, but many fine elements remain difficult to recognize and align properly
Solution Approach 1:
The light-emitting elements themselves perform the alignment function by being fitted into the guide holes of the guide member. The shape complementarity between the elements and guide holes enables self-alignment without requiring external alignment tools or visual recognition of the tiny elements
3Ease of manufacture
If array on wafer method is used, then integration formation is simplified, but flexibility in selecting and reusing individual elements is lost
Solution Approach 1:
The method separates the light-emitting elements from the wafer substrate and handles them as individual components. This segmentation allows selective picking, inspection, and reuse of specific elements while maintaining efficient batch processing capabilities through the guide member system
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 high-accuracy alignment and efficient mounting of light-emitting elements, reducing manufacturing costs and enabling the reuse of previously discarded or misaligned elements, thereby improving the manufacturing efficiency and cost-effectiveness of micro LED display devices.
Implementation Method 1
a vibration and swing mechanism to ensure precise posture and two-dimensional array alignment
Data Source
AI summary
According to one embodiment, a method of manufacturing a display device is provided. The display device includes a mounting substrate and a plurality of light-emitting elements two-dimensionally arrayed and mounted on the mounting substrate. The plurality of light-emitting elements have a planar shape that is non-rotationally symmetric and non-linearly symmetric. The method includes preparing the plurality of light-emitting elements separated from each other, preparing an array guide member, and aligning the plurality of light-emitting elements following the two-dimensional array of the opening portion group.