Micro-LED Magnetic Chuck Assembly for Uneven Display Substrates
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Solution Overview
Problem
The challenge lies in precisely positioning a large number of small semiconductor light emitting elements on a display device's wiring substrate during assembly, which is difficult due to variations in substrate surface unevenness and bending, affecting assembly efficiency.
Innovation Solution
A method and apparatus utilizing a magnetic chuck with an electromagnet to manipulate light emitting elements, adjusting magnetization intensity based on process steps, allowing precise positioning and assembly through controlled magnetic forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large number of small-sized semiconductor light emitting elements are assembled on a wiring substrate, then the display device can be implemented with desired characteristics, but it becomes very difficult to precisely position the light emitting elements at the desired positions due to substrate surface unevenness and bending
Solution Approach 1:
A magnetic chuck is introduced as an intermediary device between the assembly head and the substrate. The magnetic chuck includes a magnetic body that generates magnetic force to attract and position the light emitting elements (which contain magnetic particles) on the substrate, serving as a mediator that overcomes the positioning difficulties caused by substrate unevenness
Solution Approach 2:
The magnetic chuck includes an electromagnet whose magnetization intensity can be adjusted by changing electrical parameters (current, voltage, frequency). This allows dynamic adjustment of magnetic force strength to compensate for substrate bending and unevenness, maintaining precise positioning under varying conditions
2Productivity
If the magnetization intensity of the magnetic chuck is adjusted according to process steps, then the assembly rate is improved by accommodating substrate unevenness and bending, but the control system becomes more complex
Solution Approach 1:
The magnetic chuck transitions from a static magnetic field to a dynamic one, where the magnetization intensity can be changed in real-time according to the assembly process requirements. This dynamic adjustment capability allows the system to adapt to different assembly stages and substrate conditions, improving assembly rate
Solution Approach 2:
The electromagnet is driven by periodic electrical signals (AC power) that can be adjusted in frequency and amplitude. This periodic action allows cyclic adjustment of magnetic force intensity, enabling the system to handle substrate variations systematically throughout the assembly process
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 enhances assembly rates by optimizing magnetic force intensity for each substrate portion, accommodating unevenness and bending, thereby improving the assembly process efficiency for various substrate types.
Implementation Method 1
moving the light emitting element including a magnetic body on the substrate using a magnetic chuck having an electromagnet
Implementation Method 2
assembling the light emitting element at the individual pixel position using the magnetic chuck
Implementation Method 3
recovering a remaining light emitting element failing to be assembled at the individual pixel position using the magnetic chuck
Data Source
AI summary
Discussed is an apparatus and a method of manufacturing a display using a micro light emitting diode (LED). A method of manufacturing a display device using a light emitting element includes providing a substrate having an individual pixel position defined by a pair of assembly electrodes; moving the light emitting element including a magnetic body on to the substrate using a magnetic chuck having an electromagnet; assembling the light emitting element at the individual pixel position using the magnetic chuck; and recovering a remaining light emitting element which is not assembled at the individual pixel position using the magnetic chuck.