Micro-LED Alignment Using Vibration and Magnetic Positioning
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Solution Overview
Problem
The challenge lies in neatly arranging a large number of scattered micro-LEDs after they are detached from a growth substrate for mass transfer, as existing technologies lack an efficient method to align them effectively for high-resolution display panels.
Innovation Solution
A device comprising a carrier substrate with positioning grooves, a vibration mechanism, and a magnetic generator is used to align micro-LEDs. The carrier substrate vibrates to guide LEDs into the grooves, while the magnetic generator attracts and fixes them, ensuring precise alignment for subsequent mass transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mass transfer technology is used for batch transfer of micro-LEDs, then productivity is improved, but the ability to neatly arrange scattered micro-LEDs deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-defining positioning grooves on the carrier substrate before the micro-LEDs are transferred. These grooves are prepared in advance to receive and precisely position the scattered micro-LEDs during batch transfer, ensuring both high productivity and precise arrangement without requiring post-positioning adjustments
Solution Approach 2:
The patent introduces a carrier substrate with positioning grooves as an intermediary between the scattered micro-LEDs and the final display panel. This intermediary structure facilitates batch transfer while simultaneously providing precise positioning through the groove geometry, resolving the contradiction between mass transfer efficiency and arrangement precision
2Speed
If vibration is applied to guide LEDs into grooves, then alignment speed is improved, but control precision deteriorates
Solution Approach 1:
The patent applies mechanical vibration to the carrier substrate during the alignment process. The vibration causes scattered micro-LEDs to move and settle into the positioning grooves more quickly, significantly improving alignment speed. The groove structure ensures that even with vibrational movement, the LEDs are guided into precise positions, maintaining alignment precision despite the dynamic process
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 solution enables efficient and precise alignment of micro-LEDs, facilitating their transfer to a circuit substrate, thereby improving the resolution and arrangement of display panels.
Implementation Method 1
The vibration part 30 is configured for vibrating the carrier substrate 200 so that each LED 230 falls into a corresponding one of positioning grooves 210
Implementation Method 2
The magnetic generator 50 is configured to generate a magnetic field to attract and fix the LEDs 230 falling into the corresponding positioning grooves 210
Data Source
AI summary
A device for aligning light-emitting diodes (LEDs) by using a carrier substrate is provided. The carrier substrate defines a plurality of positioning grooves, and each positioning groove is configured for accommodating one of the LEDs. The device includes a carrying part for carrying the carrier substrate, a vibration part connected to the carrying part and for vibrating the carrier substrate, and a magnetic generator on a side of the carrier substrate away from the positioning grooves. A method for aligning LEDs is also provided.