MicroLED Element Distribution With Magnets for Uniform Display Assembly
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Solution Overview
Problem
The challenge in manufacturing large-scale microLED displays lies in the difficulty of uniformly distributing and assembling millions of semiconductor light-emitting elements on a substrate during self-assembly, leading to assembly rate deviations and non-uniform supply of red, green, and blue elements.
Innovation Solution
A method involving a distribution device with arranged magnets is used to rotate semiconductor light-emitting elements in a fluid, forming continuous patterns, and measuring pile volumes to ensure uniform distribution and controlled supply to assembly sites, followed by transferring these elements to a second chamber for self-assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If self-assembly method is used to transfer microLEDs, then large-scale display manufacturing becomes feasible, but assembly rate deviation occurs across the substrate
Solution Approach 1:
The patent applies preliminary action by pre-distributing semiconductor light-emitting elements into multiple piles at different positions before the self-assembly process. This ensures that elements are uniformly available across the substrate area, preventing assembly rate deviation and enabling large-scale display manufacturing with uniform quality.
Solution Approach 2:
The patent segments the supply of semiconductor light-emitting elements by dividing them into multiple piles positioned at different locations on the substrate. This segmentation ensures uniform distribution across the large substrate area, allowing parallel assembly processes throughout the display while maintaining consistent assembly rates.
2Quantity of substance
If semiconductor light-emitting elements are supplied in large quantities for large-scale displays, then display size increases, but uniform distribution to all assembly sites becomes difficult
Solution Approach 1:
The patent segments the large quantity of semiconductor light-emitting elements into multiple smaller piles distributed at different positions on the substrate. This segmentation maintains uniform distribution across the entire substrate area, enabling all assembly sites to receive elements simultaneously and consistently, regardless of the total number of elements.
3Manufacturing precision
If distribution device rotates to form continuous pattern, then element distribution improves, but process time increases
Solution Approach 1:
The patent uses preliminary action by rotating the distribution device to pre-form continuous patterns of semiconductor light-emitting elements before the actual self-assembly process. This preliminary distribution ensures uniform element availability across all assembly sites, and the process is optimized to complete distribution efficiently before production begins.
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 enables uniform distribution of semiconductor light-emitting elements across all assembly sites with controlled ratios, minimizing assembly rate deviations and ensuring high-quality display production.
Implementation Method 1
disposing a distribution device, on which a plurality of magnets are arranged, at one side of the first chamber
Implementation Method 2
the plurality of piles may be formed at positions corresponding to the plurality of magnets
Data Source
AI summary
A method for manufacturing a display device according to the present invention is characterized by comprising the steps of: supplying semiconductor light-emitting elements in a first chamber containing a fluid; disposing a distribution device, in which a plurality of magnets are arranged, on one side of the first chamber; rotating the distribution device such that the semiconductor light-emitting elements form a continuous pattern along the arrangement direction of the plurality of magnets; and stopping the distribution device such that the semiconductor light-emitting elements are distributed to a plurality of dummies, wherein in the step of stopping the distribution device, the plurality of dummies are formed at positions corresponding to the plurality of magnets.