Vibrating Light Plate Assembly for Precise Micro-LED Placement
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Solution Overview
Problem
The assembly of Micro-LED chips in full-color gamut displays is challenging due to high precision requirements and low mass transfer efficiency, particularly in arranging red, green, and blue chips, which are difficult to assemble and require manual intervention.
Innovation Solution
A light plate with a vibration fitting assembly that includes a vibrator and a vibration plate with installation slots, allowing light-emitting elements to be automatically aligned and installed through vibration, reducing precision needs and enabling efficient, accurate assembly without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If Micro-LED chips are arranged in sequence with high precision requirements, then the display quality is improved, but the mass transfer efficiency deteriorates
Solution Approach 1:
The patent applies vibration to the substrate during the mass transfer process, causing the transferred Micro-LED chips to self-align and settle into their correct positions. This vibration-based self-organization method simultaneously achieves high arrangement precision and maintains high mass transfer efficiency, resolving the contradiction between precision and productivity
2Measurement precision
If the size of a single RGB group is reduced, then the display resolution is improved, but the assembly difficulty increases
Solution Approach 1:
By using vibration during the transfer process, miniaturized RGB groups can be mass-transferred and automatically positioned with high precision, making assembly of small-sized display units feasible and efficient
Solution Approach 2:
The vibration process enables the transferred chips to self-organize and self-align into correct RGB group configurations automatically, reducing the need for complex manual or machine intervention in assembling miniaturized display units
3Quantity of substance
If the number of Micro-LED chips to be mass transferred is increased, then the full-color gamut display capability is improved, but the mass transfer process complexity increases
Solution Approach 1:
Vibration is applied during mass transfer to enable large numbers of chips to be transferred and automatically positioned in parallel, simplifying the overall process despite the large quantity of chips involved
Solution Approach 2:
The substrate is pre-designed with specific patterns and the vibration parameters are pre-optimized to enable automatic self-organization of chips during transfer, reducing the complexity of managing large-scale chip transfer operations
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 solution enables high-efficiency, precise installation of Micro-LED chips by automating the assembly process, reducing the need for manual handling and improving the mass transfer process efficiency and accuracy.
Implementation Method 1
the vibrator is started to drive the vibration plate to vibrate, thereby shaking the light-emitting elements, so that the positioning structure of each light-emitting element is matched and fitted with the corresponding installation slots
Data Source
AI summary
A light plate, a method for assembling a light plate, and a display device are disclosed. The light plate includes a bottom plate, a vibration fitting assembly, and multiple light-emitting elements. The vibration fitting assembly includes a vibrator, a vibration plate disposed on a side of the vibrator facing away from the bottom plate, and a support elastic piece abutting against the vibration plate. Multiple groups of installation slots are defined in the vibration plate. Each light-emitting element includes a positioning structure matching a respective group of installation slots, and is installed in the installation slots through the positioning structure. When the light-emitting elements are laid on the vibration plate, the vibrator is started to drive the vibration plate to vibrate, thereby shaking the light-emitting elements, so that the positioning structure of each light-emitting element is fitted with the installation slots to complete the installation of the light-emitting elements.