Micro-LED Light Bead Structure for Stable Mass Transfer Alignment
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Solution Overview
Problem
The mass transfer of Micro-LED chips in manufacturing processes faces challenges due to the need for high efficiency, yield, and transfer accuracy, with issues arising from rotation or flipping during installation, which affects mounting accuracy and increases process complexity.
Innovation Solution
A light bead structure with a buffer portion and counterweight portion to provide resistance and stability during mass transfer, preventing rotation or flipping, and a light plate design with magnetic attraction for precise alignment and efficient installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light bead mass transfer is performed without additional stabilization structures, then the manufacturing process remains simple, but the light bead rotates or flips during installation, reducing installation accuracy
Solution Approach 1:
The light bead is divided into distinct functional segments: a light-emitting segment, a buffer portion segment, and a counterweight portion segment. This segmentation allows each part to perform its specific function independently - the buffer portion provides resistance during installation while the counterweight provides rotational stability, thereby improving installation accuracy without requiring complete redesign of the entire light bead structure.
Solution Approach 2:
The solution moves from considering only the primary installation dimension to adding rotational stability in a different dimensional aspect. By adding the counterweight portion, the system addresses rotational dynamics (angular dimension) while the buffer portion addresses linear resistance (translational dimension), thereby controlling rotation and flipping through multi-dimensional stabilization.
2Manufacturing precision
If the light bead structure is simplified without buffer portion, then manufacturing is easier, but rotation or flipping during mass transfer reduces transfer accuracy
Solution Approach 1:
The counterweight portion is specifically designed to counteract the rotational forces and moments that cause the light bead to rotate or flip during mass transfer. By positioning mass asymmetrically in the counterweight portion, the system creates a stabilizing moment that opposes unwanted rotational motion, thereby improving mass transfer accuracy through physical counterbalancing.
Solution Approach 2:
The buffer portion and counterweight portion are pre-configured on the light bead before mass transfer occurs. This preliminary configuration ensures that the stabilization mechanisms are already in place during the mass transfer process, preventing rotation and flipping before they can affect transfer accuracy, rather than attempting to correct issues after they occur.
3Measurement precision
If buffer portion is added to prevent rotation, then installation accuracy improves, but light bead structure becomes more complex
Solution Approach 1:
The buffer portion is designed to serve multiple functions simultaneously: it provides resistance during installation to prevent rotational deviation, guides the light bead into proper alignment with the mounting slot, and works cooperatively with the counterweight portion to maintain stability. This multi-functionality allows a single component to address multiple precision requirements without proportionally increasing overall structural complexity.
Solution Approach 2:
The buffer portion acts as an intermediary element between the light bead main body and the mounting environment. It mediates the interaction during installation by providing controlled resistance and guidance, allowing the light bead to achieve precise alignment without requiring complex direct coupling mechanisms between the light bead and mounting structure.
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
Enhances the stability and precision of light bead alignment during mass transfer, improving efficiency and reducing the need for additional steps in the manufacturing process.
Implementation Method 1
During installation of the light bead, the buffer portion provides resistance to the light bead, so that the light bead is installed at the corresponding position on the light plate
Implementation Method 2
a light plate design with magnetic attraction for precise alignment and efficient installation
Data Source
AI summary
A light bead, a light plate, and a display device are disclosed. The light bead includes a light bead main body, a buffer portion, and a mating portion. The light bead main body includes a first end and a second end that are spaced apart from each other. The first end is the end of the light bead main body adjacent to a light-emitting side. The second end is the end of the light bead main body opposite to the light-emitting side. The buffer portion is arranged on the first end of the light bead main body and fits around the first end of the light bead main body. The mating portion is arranged on the second end of the light bead main body and is configured to mate with the light plate to install the light bead onto the light plate.