Microstructured Micro-LED Laser Processing With Camera Position Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in micro-LED display production is achieving high precision and economic fabrication of microstructured components with increasingly finer structures, as existing methods face limitations in positioning accuracy and cost-effectiveness, especially when dealing with large travel distances and high-resolution requirements.
Innovation Solution
A method and system utilizing camera-based position regulation and image processing to correct the positioning of micro-LEDs during laser processing, enabling precise alignment and processing even with high absolute position errors, combined with narrowband or ultraviolet light for enhanced resolution, and a beam deflection device for separate laser and observation paths, allowing for accurate and efficient micro-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera-based position regulation with image processing is implemented, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent implements a feedback control system where a camera captures images of the workpiece, image processing algorithms analyze the captured images to determine actual positions of structures, and the control unit adjusts the workpiece position based on the deviation from target positions. This closed-loop feedback mechanism continuously monitors and corrects positioning errors, achieving high positioning accuracy despite the added system complexity.
Solution Approach 2:
The patent replaces purely mechanical positioning systems with an optical-mechanical hybrid system. Instead of relying solely on mechanical precision, the system uses optical measurement (camera-based imaging) to detect position and electronic control to adjust positioning, substituting mechanical complexity with optical and computational approaches.
2Productivity
If laser processing is performed over large travel distances, then productivity is improved, but positioning accuracy deteriorates
Solution Approach 1:
The feedback control system continuously monitors the workpiece position during laser processing over large travel distances. The camera captures images at different positions, image processing determines actual coordinates, and the control unit calculates corrections to maintain accuracy throughout the entire processing area, enabling both large travel distances and high precision.
Solution Approach 2:
The patent introduces a measurement dimension (optical imaging) separate from the mechanical movement dimension. By capturing images and processing them to determine positions, the system creates an independent verification layer that compensates for accumulated mechanical positioning errors over large travel distances.
3Manufacturing precision
If micro-LED structures are miniaturized to increase resolution, then manufacturing precision is improved, but device complexity and cost increase exponentially
Solution Approach 1:
The patent uses optical measurement systems (camera-based imaging with image processing) to achieve high positioning precision without requiring proportionally high mechanical precision. This substitution allows the system to handle miniaturized micro-LED structures by relying on optical detection and electronic control rather than purely mechanical precision, avoiding exponential complexity increases.
Solution Approach 2:
The system creates optical copies (images) of the micro-LED structures to measure and control their positions. By working with optical representations rather than directly manipulating the physical structures, the system can achieve high precision for miniaturized components without the mechanical complexity that would otherwise be required.
4Measurement precision
If narrowband or ultraviolet light is used for observation, then measurement precision is improved, but use of energy increases
Solution Approach 1:
The camera-based observation system operates periodically rather than continuously, capturing images at specific intervals or at key positions during the laser processing. This periodic operation reduces energy consumption while still providing sufficient measurement precision by obtaining critical position information at strategic moments rather than maintaining constant observation.
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 ensures extremely high positioning accuracy and economic representation in micro-LED display production, enabling precise laser processing over large travel distances and maintaining high resolution, thus overcoming the limitations of existing methods.
Implementation Method 1
capturing at least one portion of the workpiece lying in the object field of a camera and also generating an image representing the portion
Implementation Method 2
capturing at least one portion of the workpiece lying in the object field of a camera and also generating an image representing the portion
Implementation Method 3
radiating in at least one laser beam directed at the workpiece to locally laser process the workpiece at at least one processing location of the workpiece
Implementation Method 4
radiating in at least one laser beam directed at the workpiece to locally laser process the workpiece
Data Source
AI summary
A method of producing a microstructured component includes a multiplicity of micro-functional elements on a substrate that carries an array of pixel-forming micro-light-emitting diodes on an electrical supply structure, including laser processing in at least one method stage in a laser processing station under control of a control unit, the method stage including positioning a workpiece to be processed in a processing position of the laser processing station by a workpiece movement system in reaction to movement signals of the control unit, the method including: observing the workpiece in a camera-based manner by a camera system, the observing including capturing at least one portion of the workpiece lying in the object field of a camera and also generating an image representing the portion; evaluating the image by image processing to ascertain position data representing an actual position of at least one structural element of the workpiece in the object field.