Micro LED Suspension Dispenser With Self-Cleaning Discharge Path
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Solution Overview
Problem
Existing micro LED transfer methods face challenges in achieving uniform discharge of micro LED suspensions onto substrates due to variations in mass concentration and clogging issues, which affect the quality and productivity of micro LED displays.
Innovation Solution
A dispenser system with a reservoir, stirrer, discharge path, filling path, hydraulic path, and washing path, equipped with valves to control the flow and pressure of the micro LED suspension, and a sprayer for uniform distribution, along with a gantry for precise substrate alignment, ensures consistent and uniform discharge and alignment of micro LEDs in a fluidic self-assembly manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the micro LED suspension is discharged repeatedly onto the substrate, then the productivity is improved, but the discharge path becomes clogged due to remaining micro LEDs, degrading uniformity of discharge
Solution Approach 1:
The washing path is configured to flush the discharge path with washing fluid before discharge to prevent clogging, and to flush after discharge to remove remaining micro LEDs. This preliminary and subsequent washing action ensures the discharge path remains clear for multiple productive discharges without degradation of uniformity.
Solution Approach 2:
A washing fluid is introduced as an intermediary substance through the washing path to clean the discharge path of remaining micro LEDs. This intermediary fluid mediates between the micro LED suspension and the discharge path, preventing direct accumulation and clogging that would otherwise occur during repeated discharge operations.
2Productivity
If the mass concentration of the micro LED suspension is increased to improve transfer efficiency, then the productivity increases, but the discharge path clogging risk increases, affecting discharge uniformity
Solution Approach 1:
The washing path utilizes hydraulic flow of washing fluid to flush and clear the discharge path of micro LEDs. This hydraulic action effectively removes accumulated particles without requiring mechanical intervention, enabling higher concentration suspensions to be discharged without clogging while maintaining productivity.
Solution Approach 2:
The system performs self-cleaning of the discharge path through the washing path configuration. The washing fluid automatically flushes remaining micro LEDs from the discharge path, enabling the system to maintain its own operational reliability without external intervention, thus supporting continuous high-productivity operation.
3Device complexity
If the discharge path is not washed between uses, then the device complexity is reduced, but the micro LED placement uniformity degrades due to clogging and mass concentration changes
Solution Approach 1:
The washing path is merged with the existing dispenser structure, sharing common components such as the reservoir, valves, and fluid delivery mechanisms. This integration allows the washing function to be added without proportionally increasing device complexity, while still achieving the goal of maintaining micro LED placement uniformity across multiple discharges.
Solution Approach 2:
The washing path utilizes the same reservoir and valve system for both micro LED suspension delivery and washing fluid delivery. This multi-functionality reduces the need for separate dedicated washing equipment, minimizing the increase in device complexity while ensuring consistent washing action that maintains placement uniformity.
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 dispenser system ensures consistent micro LED placement and alignment, maintaining uniform discharge quality even after multiple uses, thereby increasing the yield and reliability of micro LED displays by preventing clogging and ensuring constant concentration.
Implementation Method 1
a stirrer configured to stir the suspension in the reservoir
Implementation Method 2
a hydraulic path including a third valve configured to control a pressure inside the reservoir
Implementation Method 3
a washing path connected to the first valve and configured to input a washing fluid for washing the discharge path into the discharge path
Implementation Method 4
a sprayer disposed at an end of the discharge path, the sprayer being configured to spray the suspension being discharged through the discharge path
Data Source
AI summary
Provided is a dispenser for a solution including a reservoir configured to hold a suspension of micro light-emitting diodes (LEDs) suspended in a solvent; a stirrer configured to stir the suspension in the reservoir; a discharge path including a first valve configured to control outflow of the suspension from the reservoir; a filling path including a second valve configured to control inflow of the suspension into the reservoir; a hydraulic path including a third valve configured to control a pressure inside the reservoir; and a washing path connected to the first valve and configured to input a washing fluid for washing the discharge path into the discharge path, wherein the first valve includes a multi-way valve configured to selectively connect the discharge path to one of the reservoir and the washing path.