Optical Path Structure for Uniform LED Laser Transfer Spots
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Laser transfer technology for LEDs faces challenges such as mismatch between laser spot size and LED size, and poor energy uniformity, which hinders efficient separation of LEDs from carrier substrates.
Innovation Solution
An optical path structure comprising a beam adjustment module, a beam shaping module, and a beam focusing module, which adjusts the laser beam's diameter and energy homogenization to produce a target light spot that matches the LED size and ensures uniform energy distribution, allowing for precise separation of LEDs from carrier substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional laser beam is used for transfer, then the laser source is simple, but the laser spot size does not match the LED size and energy distribution is non-uniform
Solution Approach 1:
The optical path structure is segmented into three independent modules: beam adjustment module, beam shaping module, and beam focusing module. Each module performs a specific function (diameter adjustment, energy homogenization, and focal point formation), allowing precise control of laser spot characteristics while maintaining modular simplicity in the overall system design.
Solution Approach 2:
The beam shaping module applies local quality transformation by converting the non-uniform Gaussian energy distribution of the laser beam into a uniform energy distribution across the beam cross-section. This ensures that every region of the laser spot delivers consistent energy density, matching the LED chip area uniformly.
2Manufacturing precision
If the laser spot size is reduced to match small LED chips, then size matching improves, but energy uniformity deteriorates
Solution Approach 1:
The beam shaping module extracts the non-uniform energy distribution characteristic from the laser beam and replaces it with a uniform energy distribution. By separating the beam shaping function from the focusing function, the system can independently optimize both spot size and energy uniformity without compromise.
Solution Approach 2:
The system changes the energy distribution parameter of the laser beam from Gaussian (non-uniform) to uniform distribution through the beam shaping module. This parameter transformation occurs before focusing, ensuring that the final laser spot maintains both small size and uniform energy density across the entire spot area.
3Manufacturing precision
If the laser beam diameter is adjusted to match LED size, then size matching improves, but the system becomes more complex
Solution Approach 1:
The beam adjustment module employs dynamic elements such as adjustable lenses or movable optical components that can be tuned to match different LED chip sizes. This dynamic adjustability provides precise size matching for various LED dimensions while maintaining a relatively simple modular structure that can be configured for different applications.
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
The optical path structure ensures accurate alignment and uniform energy delivery, enabling efficient separation of LEDs from carrier substrates with improved size matching and energy uniformity, enhancing the transfer process.
Implementation Method 1
a beam adjustment module configured to adjust a diameter of a laser beam
Implementation Method 2
the beam shaping module includes at least one of a optical diffractive element, a optical refractive element, and a optical reflective element
Implementation Method 3
the beam shaping module includes at least one of a optical diffractive element, a optical refractive element, and a optical reflective element
Implementation Method 4
the beam shaping module includes at least one of a optical diffractive element, a optical refractive element, and a optical reflective element
Implementation Method 5
a beam focusing module configured to focus the second beam and output a target light spot
Implementation Method 6
the beam focusing module is a focusing lens or a lens group consisting of a plurality of focusing lenses
Implementation Method 7
the target light spot is used for irradiating a device substrate, allowing a target device to be separated from a carrier substrate because a bonding material, after being irradiated by the target light spot, in the device substrate changes
Implementation Method 8
the bonding material is disposed between the target device and the carrier substrate
Implementation Method 9
the first energy density is an energy density enabling the bonding material to be decomposed or gasified
Data Source
AI summary
An optical path structure, an optical path system, and a transfer method. The optical path structure includes a beam adjustment module configured to adjust a diameter of a laser beam and output a first beam; a beam shaping module configured to perform energy homogenization on the first beam to obtain a second beam; and a beam focusing module configured to focus the second beam and output a target light spot; the target light spot is used for irradiating a device substrate, so that a bonding material in the device substrate changes after being irradiated by the target light spot, and a target device is separated from a carrier substrate; where the bonding material is disposed between the target device and the carrier substrate.