Micro-LED Chip Transfer Tray With Magnetic Self-Alignment
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Solution Overview
Problem
The transfer of micro-LEDs for large-scale displays is challenging due to their small size and the difficulty in aligning and assembling millions of devices efficiently, with existing methods like pick and place having low success rates and self-assembly lacking comprehensive manufacturing technologies.
Innovation Solution
A chip tray system with a tray unit, chip alignment unit, and transfer unit that uses magnets and electric fields to align and transfer semiconductor light-emitting devices in a fluid, allowing for precise positioning and uniform distribution on a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If self-assembly method is used for transferring micro-LEDs, then large-scale display manufacturing becomes feasible, but uniformity and reliability of device positioning deteriorates
Solution Approach 1:
The patent introduces a fluid medium as an intermediary between the micro-LEDs and the substrate. The fluid allows micro-LEDs to float and self-assemble while magnetic fields provide precise positioning control, resolving the contradiction between large-scale manufacturing capability and positioning uniformity.
Solution Approach 2:
The patent replaces traditional mechanical transfer methods with a combination of fluid dynamics and magnetic field control. Micro-LEDs are transported through fluid flow and positioned using magnetic fields, enabling both high throughput and precise positioning without mechanical contact.
2Productivity
If more micro-LEDs are supplied to increase assembly density, then productivity improves, but uniformity of supply across the substrate deteriorates
Solution Approach 1:
The patent uses dynamic control of fluid flow and magnetic field strength to regulate micro-LED supply. By adjusting flow rates and magnetic field gradients, the system maintains uniform distribution of micro-LEDs across the substrate while achieving high assembly density.
Solution Approach 2:
The system incorporates feedback mechanisms to monitor micro-LED distribution and adjust fluid flow and magnetic field parameters in real-time, ensuring uniform supply across the entire substrate area while maintaining high productivity.
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-yield, low-cost assembly of large-area displays by ensuring precise alignment and uniform distribution of micro-LEDs, reducing non-specific binding and facilitating easy loading and unloading of substrates.
Implementation Method 1
a chip alignment unit including a plurality of magnets
Implementation Method 2
a transfer unit configured to move the tray unit and the chip alignment unit, the transfer unit being characterized in that the transfer unit is configured to vertically move any one of the tray unit and the chip alignment unit with respect to the other one
Data Source
AI summary
A chip transferring apparatus for supplying a micro-LED provides a chip tray for carrying semiconductor light emitting diodes in a fluid received in an assembly chamber. The transferring apparatus includes a tray unit for receiving a plurality of semiconductor light emitting diodes, a chip alignment unit disposed on one side of the tray unit and having a plurality of magnets, and a transfer unit configured to move the tray unit and the chip alignment unit. The transfer unit can vertically move one of the tray unit and the chip alignment unit with respect to the other one thereof.