SBIR Phase I: Diamagnetically Directed Self-Assembly of Light Emitting Diodes for Fabricating Large Area, Direct View Displays

小型企业创新研究(SBIR)第一阶段项目的更广泛影响/商业潜力是使颠覆性发光二极管(LED)组装技术更接近商业化，并能够创建一个变革性的低成本制造平台，这是制造未来高效高分辨率LED显示屏以及其他复杂集成电子系统所需的。该项目的成功将给大面积LED阵列组装制造带来革命性的变化，导致显示质量的显著提高，同时实现显示能耗的大幅降低，就像高效LED显著降低照明系统的能耗一样。与当前的LCD和OLED技术相比，直接查看All-LED显示屏提供了卓越的观看质量和高分辨率，并显著节省了能源。人们对分辨率越来越高的信息显示屏有着巨大的需求，但LED显示屏制造商在LED封装方面面临着非常高的成本。这种新的LED组装技术可以将极高质量LED显示屏的LED封装成本大幅降低一个数量级。这项技术还可以扩展到在太阳能系统、柔性电子产品和分布式网络电子表面等系统的大面积基板上组装任何其他类型的小型半导体管芯组件。这个小型企业创新研究(SBIR)第一阶段项目将开发并帮助将一项全新的新技术商业化，用于制造节能、高性能的直视发光二极管(LED)显示器。这项正在申请专利的技术克服了现有拾取贴片技术和目前正在开发的晶片规模冲压技术的限制。这种组装工具非常简单，成本也更低，同时实现了几乎任何LED尺寸、像素间距和显示尺寸的高得多的组装率。该项目的目标是展示这项技术的商业化可行性，并采用具有良好特征的基准工艺。将为未来的产品开发建立一套流程指标和缩放规则。该项目将产生一个原型组装系统和一个LED显示屏演示，以展示该技术对LED显示屏制造业的价值主张。

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase I project is to bring a disruptive Light Emitting Diode (LED) assembly technology closer to commercialization and enable the creation of a transformative, low cost manufacturing platform needed to manufacture future efficient high resolution LED displays as well as other complex integrated electronic systems. This project's success will revolutionize large-area LED array assembly manufacturing, leading to significant improvements in display quality, while achieving large reductions in display energy consumption, just as high efficiency LEDs have dramatically reduced energy consumption in lighting systems. Direct view all-LED displays offer superior viewing quality and high resolution at significant energy savings over current LCD and OLED technologies. There is a huge demand for information displays of increasing higher resolution, but LED display manufacturers face a very high cost in LED packaging. This new LED assembly technology can drastically reduce the LED packaging cost by an order of magnitude for extremely high quality LED displays. This technology can also be extended to the assembly of any other types of small semiconductor die components on large area substrates for systems, such as solar systems, flexible electronics, and distributed networked electronic surfaces.This Small Business Innovation Research (SBIR) Phase I project will develop and help commercialize a radically new technology for high speed, high precision assembly of small LEDs for manufacturing energy efficient, high performance direct view Light Emitting Diode (LED) displays. This patent-pending technology overcomes the limitations of incumbent pick-and-place technologies and wafer-scale stamping technologies currently in development. This assembly tool is considerably simpler and less expensive, while achieving much higher assembly rates for almost any LED size, pixel pitch and display dimensions. The objective of this project is to demonstrate the commercialization viability of this technology with well characterized baseline processes. A set of process metrics and scaling rules will be established for future product development. This project will result in a prototype assembly system and a LED display demo to demonstrate the value proposition of this technology for the LED display manufacturing industry.