Vertical Substrate Self-Assembly for Uniform Magnetic Alignment
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Solution Overview
Problem
The self-assembly of light emitting devices on large-size substrates is hindered by non-uniform magnetic field strength due to substrate warpage, leading to inconsistent pixel luminance and assembly challenges, and increased weight of magnets causing vibration and poor alignment.
Innovation Solution
A self-assembly apparatus with a vertically disposed substrate and a magnet module that maintains consistent magnetic field intensity across the assembly surface, allowing for uniform alignment and collection of light emitting devices, reducing the occupied area and improving assembly speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a magnet is moved along the horizontal direction on a large-size substrate disposed parallel to the horizontal plane, then light emitting devices can be aligned in assembly holes, but the magnetic field strength varies due to substrate warpage causing non-uniform alignment
Solution Approach 1:
The substrate is disposed vertically instead of horizontally, inverting the traditional orientation. This eliminates gravity-induced warpage and ensures the entire assembly surface is at a constant distance from the magnet, providing uniform magnetic field strength across all assembly holes for consistent light emitting device alignment
Solution Approach 2:
The substrate orientation is changed from horizontal (2D plane parallel to ground) to vertical (2D plane perpendicular to ground). This dimensional change eliminates the warpage problem caused by gravity acting on large-size substrates, ensuring uniform magnetic field distribution during self-assembly
2Productivity
If the number of magnets is increased to speed up self-assembly, then assembly speed increases, but the weight increases causing magnets to sag and contact the substrate inducing vibration
Solution Approach 1:
The vertical orientation of the substrate and magnet module counteracts the effect of gravity on the magnets. The magnets are positioned such that gravity acts perpendicular to the movement direction, preventing sagging and contact with the substrate, thereby eliminating vibration while maintaining high assembly speed
Solution Approach 2:
The magnet module is designed to move vertically along the vertical direction while the substrate remains fixed vertically. This dynamic arrangement allows multiple magnets to be used for high-speed assembly without the magnets sagging or contacting the substrate, as the vertical configuration eliminates gravity-induced deformation
3Ease of operation
If the substrate is disposed horizontally to facilitate magnet movement, then assembly process is simplified, but the central region bends downward by gravity causing non-uniform magnetic field
Solution Approach 1:
The substrate is disposed vertically instead of horizontally, inverting the traditional orientation. This eliminates gravity-induced warpage in the central region, ensuring the entire assembly surface is at a constant distance from the magnet for uniform magnetic field and precise alignment
Solution Approach 2:
The orientation parameter of the substrate is changed from horizontal to vertical. This parameter change eliminates the warpage effect caused by gravity on large-size substrates, ensuring uniform magnetic field distribution and precise alignment of light emitting devices across the entire assembly surface
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 apparatus ensures uniform luminance and high luminance by aligning a consistent number of light emitting devices per pixel, enhances assembly speed, and reduces process time and cost while preventing substrate contamination.
Implementation Method 1
a magnet module disposed on an opposite surface opposite to the assembly surface of the substrate
Implementation Method 2
The light emitting devices are moved along the moving direction of the magnet positioned on the substrate
Implementation Method 3
the light emitting devices are aligned in the corresponding assembly hole by the dielectrophoretic force between the wiring electrodes
Implementation Method 4
When the substrate of the 8th generation (2200 mm×2500 mm) or higher is disposed parallel to the horizontal plane of the chamber, a central region of the substrate is bent downward by gravity
Data Source
AI summary
Discussed is a self-assembly apparatus that can include a chamber, at least one first supply part configured to supply a fluid to the chamber, a mounting part disposed on a first side of the chamber to mount a substrate to be inclined with respect to a horizontal plane of the chamber, the substrate having an assembly surface, and a magnet module disposed on an opposite surface of the substrate opposite to the assembly surface of the substrate, wherein the mounting part is configured to: insert the substrate into an upper side of the chamber, guide the inserted substrate from the upper side of the chamber toward a lower side of the chamber, and fix the guided substrate to the lower side of the chamber.