Method of manufacturing an LED carrier assembly having an embedded alignment magnet

1. A method of manufacturing an LED carrier assembly, the method comprising:

providing a carrier comprising a mounting surface with a plurality of pairs of mounting pads, each of the plurality of pairs of mounting pads comprising a first mounting pad and a second mounting pad;

fully embedding a plurality of alignment magnets in the carrier such that each of the plurality of alignment magnets is disposed underneath a respective one of the plurality of pairs of mounting pads;

providing a plurality of LED dies, each of the plurality of LED dies comprising an n-type region, a p-type region, a light-emitting region between the n-type region and the p-type region, and a pair of magnetic die pads, a first magnetic die pad of the pair of magnetic die pads being electrically coupled to the n-type region and a second magnetic die pad of the pair of magnetic die pads being electrically coupled to the p-type region; and

aligning each of the plurality of LED dies with a respective one of the plurality of pairs of mounting pads by arranging the plurality of LED dies over the mounting surface of the carrier, each within magnetic range of one of the plurality of alignment magnets such that the first magnetic die pad of each of the pairs of LED dies is magnetically coupled to the first mounting pad of the opposing pair of mounting pads with an attractive force of at least 0.4 mN and the second magnetic die pad of each of the pairs of LED dies is magnetically coupled to the second mounting pad of the opposing pair of mounting pads with the attractive force of at least 0.4 mN such that the plurality of LED dies are mounted on the carrier without use of an adhesive.

2. The method according to claim 1 , wherein the embedding the plurality of alignment magnets comprises embedding the plurality of alignment magnets to a depth of at most 2.0 mm below the mounting surface of the carrier.

3. The method according to claim 1 , wherein the embedding the plurality of alignment magnets comprises embedding the plurality of alignment magnets such that an upper surface of the plurality of alignment magnets is essentially flush with the mounting surface of the carrier.

4. The method according to claim 1 , further comprising at least one of:

applying an electrically conductive grease to the plurality of mounting pads prior to aligning each of the pair of magnetic die pads to one of the plurality of mounting pads; and

applying a protective coating to at least one of the pair of magnetic die pads.

5. The method according to claim 1 , further comprising:

submerging the mounting surface of the carrier in a liquid; and

floating the plurality of LED dies on the liquid in preparation for the aligning.

6. The method according to claim 1 , further comprising applying a covering layer over the aligned LED dies to fix the positions of the aligned LED dies relative to the carrier.

7. The method according to according to claim 6 , wherein the covering layer comprises a material that undergoes shrinkage upon curing.

8. The method of claim 1 , wherein the alignment magnet is a permanent magnet.

9. An LED carrier assembly comprising:

a carrier comprising a mounting surface with a plurality of pairs of mounting pads, each of the plurality of pairs of mounting pads comprising a first mounting pad and a second mounting pad;

a plurality of alignment magnets fully embedded within a body of the carrier, each of the plurality of alignment magnets disposed underneath a respective one of the plurality of pairs of mounting pads; and

a plurality of LED dies, wherein each of the plurality of LED dies comprises an n-type region, a p-type region, a light-emitting region between the n-type region and the p-type region, and a pair of magnetic die pads, a first magnetic die pad of the pair of magnetic die pads being electrically coupled to the n-type region and a second magnetic die pad of the pair of magnetic die pads being electrically coupled to the p-type region,

each of the plurality of LED dies disposed on the carrier opposite a respective one of the plurality of pairs of mounting pads, and the plurality of alignment magnets and each pair of magnetic die pads being configured to magnetically couple the first magnetic die pad of each of the pairs of LED dies to the first mounting pad of the opposing pair of mounting pads and the second magnetic die pad of each of the pairs of LED dies to the second mounting pad of the opposing pair of mounting pads with an attractive force of at least 0.4 mN such that the plurality of LED dies are mounted on the carrier without use of an adhesive.

10. The LED carrier assembly according to claim 9 , wherein at least one of a thickness of each of the plurality of alignment magnets and a side length of each of the plurality of alignment magnets comprises at least 0.1 mm and at most 2.0 mm.

11. The LED carrier assembly according to claim 9 , wherein each of the plurality of alignment magnets is a permanent magnet.

12. The LED carrier assembly according to claim 9 , wherein corresponding ones of the plurality of alignment magnets and corresponding ones of the plurality of pairs of magnetic die pads each comprise a magnetization direction parallel to the mounting surface of the carrier.

13. The LED carrier assembly according to claim 9 , wherein each of the plurality of pairs of magnetic die pads comprises at least one of a magnetic anode die pad and a magnetic cathode die pad.

14. The LED carrier assembly according to claim 9 , wherein a relative permeability of each of the magnetic die pads in the plurality of pairs of magnetic die pads comprises at least 5,000.

15. The LED carrier assembly according to claim 9 , wherein at least one of the dimensions, material properties and relative positions of each of the plurality of alignment magnets and the magnetic die pads are chosen to achieve an attractive force of at least 0.6 mN between each of the plurality of pairs of magnetic die pads and the alignment magnet under each of the plurality of pairs of magnetic die pads.

16. The LED carrier assembly according to claim 9 , wherein at least one of the dimensions, material properties and relative positions of each of the plurality of alignment magnets and the magnetic die pads are chosen to achieve an attractive force of at least 0.8 Mn between each of the plurality of pairs of magnetic die pads and the alignment magnet under each of the plurality of pairs of magnetic die pads.

17. The LED carrier assembly according to claim 9 , wherein each of the plurality of alignment magnets is a body of ferromagnetic material.

18. The LED carrier assembly according to claim 9 , wherein each of the plurality of alignment magnets is embedded to a depth of at most 2.0 mm below the mounting surface of the carrier.

19. The LED carrier assembly according to claim 9 , wherein an upper surface of each of the plurality of alignment magnets is essentially flush with the mounting surface of the carrier.