UV Adhesive Layering for Precise LED Array Element Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for replacing defective light-emitting elements in densely packed arrays are inaccurate due to miniaturization and reduced spacing, making precise removal and replacement challenging.
Innovation Solution
A method involving a stacked structure with ultraviolet-reactive adhesive layers and shielding, followed by targeted ultraviolet irradiation to selectively separate defective elements, utilizing adhesive force manipulation to ensure accurate replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If light-emitting elements are reduced in size and spaced closer together to increase density, then the number of elements per substrate increases, but the accuracy of selective replacement deteriorates
Solution Approach 1:
The adhesive layer is segmented into different regions with different UV transmittance characteristics. The first adhesive layer has high UV transmittance while the second adhesive layer has low UV transmittance, allowing selective separation of specific light-emitting elements based on their position. This segmentation enables precise control over which elements are replaced without affecting adjacent elements, even in densely packed arrays.
Solution Approach 2:
Different regions of the adhesive layer are given different local qualities in terms of UV transmittance. The first adhesive layer region is designed to transmit UV light for selective separation, while the second adhesive layer region blocks UV light to maintain adhesion. This local differentiation allows accurate selective replacement of individual elements while maintaining the integrity of the overall dense array.
2Stability of the object's composition
If adhesive force is increased to secure elements firmly, then element stability improves, but ease of selective removal deteriorates
Solution Approach 1:
The adhesive force parameter is changed spatially across different regions of the adhesive layer. By controlling the UV transmittance characteristics of the first and second adhesive layers, the adhesive force is made strong in regions where elements should remain fixed and weak in regions where selective removal is desired. This parameter differentiation allows elements to be stably mounted while enabling easy selective removal when needed.
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 precise removal and replacement of defective light-emitting elements, maintaining accuracy even with miniaturized and closely spaced elements, ensuring high precision in the manufacturing process.
Implementation Method 1
performing first ultraviolet irradiation of irradiating the intermediate body with ultraviolet from a direction facing the ultraviolet shielding layer; performing second ultraviolet irradiation of irradiating the intermediate body with ultraviolet from a direction facing the first ultraviolet transmitting layer
Data Source
AI summary
A method for manufacturing a light-emitting device includes: providing an intermediate body having a first ultraviolet transmitting layer, a first adhesive layer, a plurality of first light emitting elements, a second adhesive layer, and a second ultraviolet transmitting layer; disposing on the second ultraviolet transmitting layer of the intermediate body, an ultraviolet shielding layer in a region corresponding to a part of the first light-emitting elements; performing first ultraviolet irradiation of irradiating the intermediate body with ultraviolet from a direction facing the ultraviolet shielding layer; performing second ultraviolet irradiation of irradiating the intermediate body with ultraviolet from a direction facing the first ultraviolet transmitting layer; and separating the part of the first light-emitting elements from the first adhesive layer along with the second adhesive layer.