Pick-Up Tool Molded Elastomeric Optics for LED Brightness
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Solution Overview
Problem
The fabrication of semiconductor devices, such as tiny LEDs, is challenged by the limitations in brightness due to their small size and the separate alignment processes for device pick-up and optics formation, which can introduce errors.
Innovation Solution
The use of an elastomeric material on semiconductor devices allows for a pick-up tool with molded optical elements to adhere and form optical elements concurrently, reducing errors by aligning both pick-up and optics formation processes simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate alignment processes are used for device pick-up and optics formation, then each process can be optimized independently, but alignment errors accumulate and manufacturing precision deteriorates
Solution Approach 1:
The patent combines the pick-up tool and optics formation mold into a single integrated tool structure. The pick-up surface includes both adhesion functionality for device pick-up and molded cavities for forming optical elements. This merging eliminates the need for separate alignment processes, preventing error accumulation and improving manufacturing precision while reducing overall process complexity.
Solution Approach 2:
The pick-up tool is designed with multi-functionality, serving both as a device pick-up mechanism through adhesion and as an optics formation mold through its molded cavities. This universal tool performs multiple functions in a single operation, eliminating the need for separate specialized tools and alignment processes, thereby improving alignment precision without proportionally increasing device complexity.
2Length of moving object
If tiny LEDs are used to reduce size, then device dimensions are reduced, but brightness capability deteriorates
Solution Approach 1:
The patent introduces optical elements (lenses or diffraction gratings) formed on the LED surface as intermediary structures. These optical elements act as mediators that enhance the light output of tiny LEDs by focusing or directing the emitted light more effectively. The elastomeric material serves as both the pick-up interface and the medium for forming these optical enhancement structures, allowing tiny LEDs to achieve improved brightness without increasing their physical size.
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 enhances the brightness of LEDs by forming optical elements like lenses or diffraction gratings, improving the fabrication accuracy and reducing errors in the semiconductor device fabrication process.
Implementation Method 1
The elastomeric material enables a pick-up tool (PUT) to adhere to the LEDs
Implementation Method 2
The elastomeric material can also be molded into optical elements that increase the brightness of the LEDs
Implementation Method 3
forming optical elements like lenses or diffraction gratings
Data Source
AI summary
Techniques related to optics formation using pick-up tools are disclosed. Optical elements are formed by pressing a pick-up tool (PUT) against elastomeric material deposited on a light-outputting side of light-emitting diode (LED) devices. Pressing the PUT against the elastomeric material causes a molded shape of the PUT to be transferred to the elastomeric material. This forms the optical elements in the elastomeric material.