Micro-LED Assembly Signal Control for Fast, Accurate Placement
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Solution Overview
Problem
The existing methods for manufacturing large micro-LED displays face challenges in quickly and accurately transferring millions of micro-LEDs to the display panel, leading to long process times and color mixing defects due to incorrect assembly.
Innovation Solution
A device for manufacturing a display device that includes a chamber with a display substrate and a fluid, a magnetic member, and a signal supply device. The signal supply device modulates an alternating current signal to periodically change the dielectrophoretic force, allowing for simultaneous assembly of micro-LEDs and the detachment of incorrectly assembled ones to improve assembly accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If simultaneous assembly method is used to assemble multiple semiconductor light-emitting elements, then process time is dramatically reduced, but color mixing defects occur due to incorrect assembly
Solution Approach 1:
The patent applies local quality by creating distinct assembly environments for different colored semiconductor light-emitting elements. Each color type (red, green, blue) is assigned to a specific assembly hole location on the display substrate, with corresponding local magnetic fields generated by electrode wiring. This spatial differentiation ensures that each element type is attracted to its correct position, preventing color mixing defects while maintaining simultaneous assembly of multiple elements.
Solution Approach 2:
The patent implements feedback through the magnetic field generation mechanism. When an alternating current signal is applied to the electrode wiring, magnetic fields are generated that provide real-time feedback control for element positioning. The magnetic fields dynamically adjust to guide semiconductor light-emitting elements to their correct assembly holes, enabling automatic correction and ensuring high assembly accuracy during simultaneous assembly operations.
2Manufacturing precision
If individual assembly method is used for each semiconductor light-emitting element, then assembly accuracy is maintained, but process time becomes excessively long
Solution Approach 1:
The patent merges multiple individual assembly operations into a single simultaneous assembly process. By applying alternating current signals to the electrode wiring, magnetic fields are generated that simultaneously guide multiple semiconductor light-emitting elements of different colors to their respective assembly holes in parallel. This combining of operations maintains the accuracy of individual assembly while achieving the productivity of simultaneous assembly.
Solution Approach 2:
The patent employs periodic action through alternating current signals applied to the electrode wiring. The periodic magnetic fields generated by the alternating current create rhythmic attraction and release cycles that guide semiconductor light-emitting elements to their correct positions. This periodic action enables simultaneous manipulation of multiple elements while maintaining precise control over each element's placement, solving the contradiction between speed and accuracy.
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 solution dramatically shortens the process time for assembling micro-LEDs on a display substrate, enhances the correct assembly rate, and prevents color mixing defects, thereby improving the reliability of the display device.
Implementation Method 1
the signal supply device is configured to modulate a first alternating current signal into a second alternating current signal and to supply the modulated second alternating current signal to electrode wiring of the display substrate, and the second alternating current signal is configured to periodically change a dielectrophoretic force to attach and detach a plurality of semiconductor light-emitting elements contained in the fluid to a plurality of assembly holes of the display substrate
Data Source
AI summary
A manufacturing device for a display device comprises: a chamber in which a display substrate is installed and comprises a fluid; a magnetic member on one side of the display substrate; And a signal supply device is included, wherein the signal supply device modulates a first alternating current signal into a second alternating current signal and supplies the modulated second alternating current signal to electrode wiring of the display substrate, and the second alternating current signal periodically changes a dielectrophoretic force to attach and detach a plurality of semiconductor light-emitting elements contained in the fluid to a plurality of assembly holes of the display substrate, respectively.