Vacuum LED Transfer Chamber for Precise Backplane Bonding
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Solution Overview
Problem
Challenging to attach light-emitting diodes (LEDs) to a backplane with high yield in electronic displays.
Innovation Solution
An apparatus and method involving a backing board, sealing member, transparent panel, vacuum source, and laser radiation source to transfer LEDs by drawing a vacuum and using laser radiation to irradiate LEDs on a backplane, facilitating precise alignment and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to attach LEDs to a backplane, then the process is simpler, but the bonding yield and quality are low
Solution Approach 1:
The transfer apparatus segments the LED attachment process into distinct functional zones: a vacuum chamber for precise positioning, a laser radiation source for bonding, and a support structure for the backplane. This segmentation allows each component to perform its specific function optimally, achieving high bonding yield while maintaining manageable system complexity through modular design
Solution Approach 2:
The patent introduces a vacuum chamber as an intermediary environment between the LED source and backplane. This vacuum environment serves as a mediator that enables precise positioning and control during the transfer process, significantly improving bonding quality without requiring direct complex mechanical manipulation
2Manufacturing precision
If manual or conventional automated methods are used for LED transfer, then the equipment is simpler, but the alignment precision and bonding accuracy are insufficient
Solution Approach 1:
The patent replaces complex mechanical alignment systems with a vacuum-based positioning system combined with laser radiation for bonding. The vacuum chamber provides stable, precise positioning without requiring complex mechanical stages, while the laser source delivers accurate bonding with high spatial precision, achieving superior manufacturing precision with reduced mechanical complexity
Solution Approach 2:
The invention changes the physical parameter of the transfer environment from atmospheric pressure to vacuum. This parameter change fundamentally improves alignment precision by eliminating air interference and enabling better control of the transfer process, while the vacuum system itself remains relatively simple in structure
3Reliability
If pressure is applied to ensure LED contact with backplane, then bonding contact is improved, but non-uniform pressure causes defects and damage
Solution Approach 1:
The patent uses vacuum pressure (a pneumatic principle) applied uniformly across the entire LED array in the vacuum chamber. This uniform vacuum pressure ensures consistent contact between all LEDs and the backplane without the non-uniform localized pressure that causes defects, achieving high bonding quality while avoiding pressure-related damage
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
Improves the bonding quality and accuracy of LEDs to a backplane, enhancing display device yield by reducing non-uniformity and damage during the transfer process.
Implementation Method 1
a vacuum source configured to draw a vacuum on the space
Implementation Method 2
drawing a vacuum on the space such that the transparent panel presses the plurality of first LED coupons toward the backplane
Implementation Method 3
a laser radiation source that is configured to direct a laser radiation through the transparent panel to irradiate a LED coupon on the backplane in the space
Data Source
AI summary
An apparatus for transferring light-emitting diodes (LEDs) includes a backing board for supporting a backplane, a sealing member formed on the backing board around a periphery of the backplane, a transparent panel formed on the sealing member such that a space is formed between the backing board and the transparent panel, and a vacuum source for drawing a vacuum on the space.