Micro-LED Chip Dispenser for Uniform Self-Assembly Transfer
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Solution Overview
Problem
Existing technologies face challenges in efficiently transferring and assembling millions of micro-sized semiconductor light emitting devices for large-screen displays, particularly in maintaining high reliability and yield during the self-assembly process.
Innovation Solution
A chip dispenser is designed with a body part, pressure controller, stirring part, and magnet transfer unit to supply semiconductor light emitting devices at a constant amount and interval, utilizing magnetic and electric fields for precise placement on a substrate, minimizing non-specific assembly and facilitating high-speed, low-cost transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If self-assembly method is used for transferring micro-LED devices, then large screen display manufacturing becomes feasible, but manufacturing precision and reliability are insufficient
Solution Approach 1:
The patent replaces traditional mechanical pick-and-place systems with a self-assembly approach using fluid dynamics and magnetic fields. Micro-LED devices are suspended in a fluid and guided to target positions through controlled magnetic forces, eliminating mechanical contact and improving both precision and scalability for large screens.
Solution Approach 2:
The patent introduces a fluid medium as an intermediary to suspend and transport micro-LED devices. The fluid allows devices to move freely to their target positions while magnetic fields provide precise positioning control, resolving the contradiction between mass transfer capability and placement precision.
2Productivity
If conventional transfer methods are used, then device transfer is possible, but transfer speed and efficiency are insufficient for millions of devices
Solution Approach 1:
The patent enables micro-LED devices to self-assemble at their target positions through the interaction of magnetic fields and fluid flow. Devices automatically navigate to correct locations without external manipulation, dramatically increasing transfer speed while maintaining reliability through consistent physical laws governing the self-assembly process.
3Manufacturing precision
If additional devices or processes are added to improve placement precision, then positioning accuracy improves, but device complexity and cost increase
Solution Approach 1:
The patent uses a multi-functional system where the fluid medium serves multiple purposes: suspending devices, enabling movement, and facilitating heat dissipation. The magnetic field system simultaneously provides both positioning and orientation control, achieving high precision without adding separate complex subsystems.
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
Enables high-efficiency, high-speed transfer of semiconductor light emitting devices with precise positioning, reducing costs and improving yield in large-area display manufacturing by ensuring uniform dispersion and selective assembly without additional devices or processes.
Implementation Method 1
the pressure controller can inject a predetermined volume of gas into the body part when increasing the internal pressure of the body
Implementation Method 2
a stirring part disposed in at least one of the inside and outside of the body part, agitating the fluid accommodated in the body part
Implementation Method 3
it can further include a chip leakage prevention part having at least one magnet and a magnet transfer unit configured to vary a distance between the at least one magnet and the nozzle part
Data Source
AI summary
The present invention relates to a method of manufacturing a display device, and more particularly, to a chip dispenser for supplying a micro-LED. The present invention provides a chip dispenser including a body part for accommodating the fluid and the semiconductor light emitting device, and discharging the accommodated fluid and the semiconductor light emitting device, a pressure controller for varying the pressure inside the body; and a stirring part disposed in at least one of the inside and outside of the body, agitating the fluid accommodated in the body and the pressure controller increases the internal pressure of the body part so that the fluid and the semiconductor light emitting device are discharged to the outside in a state in which the agitating part stirs the fluid.