Sliding Pin Ejection for Continuous Mini-LED Mass Transfer
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Solution Overview
Problem
Existing pin-ejector transfer technologies for Mini/Micro LED chips suffer from limited transfer efficiency and precision due to intermittent motion platform pauses, which also lead to wear and tear on the motion platform.
Innovation Solution
The introduction of an ejector pin sliding on membrane-based device, which uses a gantry transverse beam, a blue membrane with Mini-LED chips, and a transfer substrate, enables a sliding-on-membrane pin ejection method that avoids intermittent pauses and enhances transfer efficiency and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If intermittent pin-ejector transfer is used, then chip transfer can be completed with simple mechanism, but transfer efficiency is greatly limited and motion platform service life is reduced
Solution Approach 1:
The patent implements continuous pin-ejector transfer where the motion platform moves continuously without intermittent pauses. The ejector pin base maintains uniform movement throughout the process, and the ejector pin coordinates with voice coil motors to achieve precise chip ejection during continuous motion, thereby eliminating time loss from repeated starting and stopping while maintaining transfer efficiency
2Manufacturing precision
If intermittent pin-ejector transfer is used, then mechanism structure is simple, but packaging precision is greatly reduced due to shake from starting and pausing
Solution Approach 1:
The motion platform performs continuous movement without intermittent pauses, eliminating the shake and vibration caused by repeated starting and stopping. This continuity maintains high packaging precision while the added complexity of voice coil motors and flexible mechanisms is justified by the significant improvement in transfer accuracy and platform service life
Solution Approach 2:
The patent changes the motion parameters from intermittent to continuous, and uses voice coil motors to dynamically adjust the ejector pin position during continuous motion. This parameter change enables precise chip ejection during uniform motion, achieving high packaging precision without the harmful effects of intermittent pausing
3Productivity
If continuous pin-ejector transfer is used, then transfer efficiency is improved, but vertical pin ejection method has defects that need optimization
Solution Approach 1:
The patent transitions from purely vertical pin ejection to a sliding-on-membrane ejection method where the ejector pin moves horizontally along the blue membrane to reach the chip. This dimensional change from vertical-only to horizontal-sliding motion enables more reliable chip engagement and ejection, improving the reliability of the transfer process while maintaining continuous motion for high efficiency
Data Source
AI summary
An ejector pin sliding on membrane-based device and method for mass transfer of mini light-emitting diodes (Mini-LEDs) are provided. The device includes a gantry transverse beam. The gantry transverse beam is provided with an ejector pin base, and the ejector pin base is configured to move along the gantry transverse beam. The ejector pin base is fixedly provided with a vision camera and an ejector pin. A blue membrane is horizontally provided at a side of the gantry transverse beam close to the ejector pin, and is spaced from the gantry beam. A surface of a side of the blue membrane away from the gantry transverse beam is adhesively provided with a plurality of Mini-LED chips arranged evenly. A transfer substrate is horizontally provided at a side of the blue membrane close to the plurality of Mini-LED chips, and is spaced from the blue membrane.