Micro LED Grip Body Vacuum Transfer Precision

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Solution Overview

Problem

Current methods for transferring micro LEDs to display substrates face challenges such as damage from electrostatic charges, adhesive force issues, manufacturing difficulties, and the need for additional processes, which limit the precision and reliability of micro LED handling and mounting.

Innovation Solution

A micro LED grip body with a porous member and a mask below it, which increases vacuum pressure through openings, allowing for precise vacuum-suction and transfer of micro LEDs without deviation, using materials like Invar, metal, film, or paper for the mask to enhance grip and prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If an electrostatic head is used to transfer micro LEDs, then the transfer precision is improved, but micro LEDs may be damaged due to electrification caused by voltage applied to the head portion

Engineering Contradiction:

Improvetransfer precisionVSAvoidelectrification damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the electrostatic head mechanism with a mechanical grip body system that uses vacuum suction through porous members. This substitution eliminates the harmful electrification effect while maintaining precise transfer capability through controlled vacuum pressure applied to the micro LED surfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a porous member as an intermediary between the grip body and the micro LED. This porous member enables vacuum pressure transmission while providing a gentle contact surface that prevents damage to the fragile micro LED structure during transfer.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If an elastic polymer material is used as a transfer head, then LED damage from electrification is prevented, but adhesive force must be higher than the target substrate and additional electrode formation process is required

Engineering Contradiction:

Improveelectrification damage preventionVSAvoidadditional electrode formation process

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the adhesive layer and electrode formation requirements by using a vacuum-based grip system. The porous members provide sufficient holding force through vacuum pressure alone, removing the need for additional adhesive materials and electrode fabrication steps.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs vacuum pressure (pneumatic principle) to create the gripping force instead of relying on adhesive materials. The vacuum suction applied through the porous members provides controlled, uniform holding force that eliminates the need for adhesive layers and subsequent electrode formation processes.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Manufacturing precision

If a ciliary adhesive-structured head is used to transfer micro LEDs, then transfer capability is improved, but manufacturing difficulty increases

Engineering Contradiction:

Improvetransfer capabilityVSAvoidmanufacturing difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent uses porous members with controlled pore structures to provide the necessary grip and transfer capability. These porous members can be manufactured using standard ceramic or polymer processing techniques, avoiding the complex ciliary adhesive structure while achieving effective micro LED handling through vacuum pressure distribution.

Inventive Principle:

Principle #31Porous materials

4Productivity

If a roller coated with adhesive is used to transfer micro LEDs, then continuous transfer is possible, but micro LEDs may be damaged when pressed with the roller and continuous adhesive application is required

Engineering Contradiction:

Improvecontinuous transfer capabilityVSAvoidmechanical damage from pressing

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical pressing action of a roller with a vacuum suction system. The porous members distribute vacuum pressure uniformly across the micro LED surfaces, eliminating concentrated mechanical stress that causes damage while enabling continuous transfer through sustained vacuum application.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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

The solution provides a reliable and precise method for transferring micro LEDs, preventing deviation and damage by increasing vacuum pressure and ensuring uniform flatness, thus improving the handling and mounting process for micro LEDs on display substrates.

Implementation Method 1

a porous member having pores; and a mask provided below the porous member and having an opening

Methodology Applied

Scientific EffectVacuum suction: Vacuum

Data Source

PatentUS10629471B2Micro LED grip body

Publication Date: 2020.04.21 POINT ENG

AI summary

The present invention relates to a micro LED grip body for vacuum-sucking micro LEDs. More particularly, the present invention relates to a micro LED grip body provided with a mask below a porous member to increase vacuum pressure for vacuum-sucking micro LEDs such that the micro LEDs are transferred without deviation.