Manufacturing apparatus for display device

Abstract

The invention relates to a manufacturing apparatus for a display device. According to an embodiment of the present disclosure, a manufacturing apparatus for a display device includes: a stage including a substrate placement area configured to place a substrate and a peripheral area provided around the substrate placement area; a dispenser disposed above the stage and including a nozzle for discharging the ink; and a gap measuring unit at least partially disposed in a surrounding area of the stage. The gap measurement unit includes a reference block and a camera facing the reference block.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority from and all rights arising from Korean Patent Application No. 10-2024-0049324 filed in the Korean Intellectual Property Office on April 12, 2024, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure relates to a manufacturing apparatus and method for a display device. Background Art

[0004] As the information society progresses, the demand for display devices for displaying images is increasing in various forms. For example, display devices are being applied to various electronic devices such as smartphones, digital cameras, laptop computers, navigation systems, and smart TVs.

[0005] Various types of display devices are being used, such as liquid crystal displays (LCDs) and organic light emitting diode (OLED) display devices.

[0006] The manufacture of a display device may involve a coating process of applying a sealant of an adhesive material to a substrate to bond the substrate to another substrate or another structure.

[0007] During sealant coating, a dispenser including a nozzle is used to discharge the sealant onto the substrate. The amount of sealant discharged can be adjusted based on the gap between the substrate and the nozzle. Therefore, measuring and calibrating the gap between the substrate and the nozzle is crucial. However, if gap calibration is not performed accurately, the amount of sealant discharged through the nozzle may become inaccurate, potentially causing variations in the desired line width and coating quality, leading to process dispersion. Summary of the Invention

[0008] Aspects of the present disclosure provide an apparatus and method for manufacturing a display device capable of performing gap calibration in a non-contact manner.

[0009] According to an embodiment of the present disclosure, a manufacturing apparatus for a display device includes: a stage including a substrate placement area and a peripheral area disposed around the substrate placement area, the substrate placement area being configured to place a substrate; a dispenser disposed above the stage and including a nozzle for discharging ink; and a gap measurement unit disposed at least partially within the peripheral area of ​​the stage. The gap measurement unit includes a reference block and a camera facing the reference block.

[0010] In an embodiment, a stage includes: a stage body including a substrate seating area; and an auxiliary frame provided at one side of the stage body, and the gap measurement unit is arranged to overlap with the auxiliary frame.

[0011] In an embodiment, the upper surface of the reference block and the upper surface of the substrate are arranged in the same plane.

[0012] In an embodiment, the manufacturing apparatus further comprises: a dispenser vertical driver to vertically move the dispenser relative to the substrate and the reference block, wherein in the surrounding area, the dispenser is vertically raised or lowered between the reference block and the camera by the dispenser vertical driver.

[0013] In an embodiment, the manufacturing apparatus further includes: a storage unit storing a driving value of the dispenser vertical driver based on a measurement result of the gap from the camera; and a control unit controlling the dispenser vertical driver to raise and lower the dispenser.

[0014] In an embodiment, if the measurement result indicates that the gap matches the reference set value, the control unit stores the driving value of the dispenser vertical driver in the storage unit and moves the dispenser in the surrounding area to the substrate seating area.

[0015] In an embodiment, the manufacturing apparatus further comprises a lookup table storing the drive value of the dispenser vertical driver as a data value.

[0016] In an embodiment, the manufacturing apparatus further includes a height adjustment device coupling the auxiliary frame to be adjustable in height relative to the stage main body.

[0017] In an embodiment, the reference block is arranged on the auxiliary frame at a position spaced apart from the base plate in the first direction, and the camera is provided behind the reference block in the first direction.

[0018] In an embodiment, the manufacturing apparatus further includes: a base frame supporting the stage from below; a stage transfer unit moving the stage in the first direction; and a dispenser support unit coupling the dispenser to the base frame.

[0019] In an embodiment, the reference block has a long strip shape along a second direction perpendicular to the first direction, and a plurality of cameras including the camera are provided along the second direction.

[0020] According to an embodiment of the present disclosure, a manufacturing method for a display device includes: setting a dispenser including a nozzle above a display device substrate placed on a stage; moving the dispenser to a gap calibration area, which is arranged away from the stage along a first direction and in which a gap measurement unit including a reference block and a camera is arranged; measuring the gap between the upper surface of the reference block and the tip of the nozzle in the gap calibration area using a camera; and when it is concluded that the gap matches a reference set value based on a result of measuring the gap, moving the dispenser away from the gap calibration area.

[0021] In an embodiment, the manufacturing method further includes storing a driving value of a dispenser vertical driver that vertically moves the dispenser with respect to the substrate and the reference block based on a result of measuring the gap.

[0022] In an embodiment, wherein moving the dispenser comprises moving the dispenser from the gap calibration area to a discharge position above the substrate.

[0023] In an embodiment, the manufacturing method further includes ejecting the liquid onto the substrate at the discharge location while raising the dispenser based on the stored drive value.

[0024] In an embodiment, the manufacturing method further includes: additionally measuring the gap during the ejection of the liquid; and additionally storing a driving value of the dispenser vertical driver based on a result of the additional measurement of the gap.

[0025] According to an embodiment of the present disclosure, a manufacturing method for a display device includes: setting a dispenser including a nozzle above a display device substrate placed on a stage; moving the dispenser to a gap calibration area, which is arranged away from the stage in a first direction and in which a gap measurement unit including a reference block and a camera is arranged; measuring the gap between the upper surface of the reference block and the tip of the nozzle in the gap calibration area using a camera; and calibrating the gap by raising or lowering the dispenser using a dispenser vertical driver based on a result of measuring the gap.

[0026] In an embodiment, the manufacturing method further includes: storing a driving value of a vertical driver of the dispenser based on a result of measuring the gap; and moving the dispenser from the gap calibration area to a discharge position above the substrate.

[0027] In an embodiment, the manufacturing method further includes ejecting the liquid onto the substrate at the discharge location while raising the dispenser based on the stored drive value.

[0028] In an embodiment, the measuring gap and the calibration gap are repeated at least once during the injection of the liquid.

[0029] According to the above and other embodiments of the present disclosure, gap calibration with excellent reproducibility can be performed in a non-contact manner.

[0030] It should be noted that the effects of the present disclosure are not limited to those described above, and other effects of the present disclosure will be apparent from the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The above and other aspects and features of the present disclosure will become more apparent by describing in detail exemplary embodiments of the present disclosure with reference to the attached drawings.

[0032] Figure 1is a perspective view of a manufacturing apparatus for a display device according to an embodiment.

[0033] Figure 2 The diagram shows Figure 1 Top view of the substrate, stage, and gap measurement unit.

[0034] Figure 3 is a top view of a manufacturing apparatus for a display device according to an embodiment of the present disclosure.

[0035] Figure 4 is a block diagram of a manufacturing apparatus for a display device according to an embodiment of the present disclosure.

[0036] Figure 5 is a block diagram of a manufacturing apparatus for a display device according to an embodiment of the present disclosure.

[0037] Figure 6 is a flowchart illustrating a gap calibration method for a manufacturing apparatus of a display device according to an embodiment of the present disclosure.

[0038] Figure 7 is a flowchart illustrating a gap calibration method for a manufacturing apparatus of a display device according to an embodiment of the present disclosure.

[0039] Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 、 Figure 13 and Figure 14 The figure illustrates a gap calibration process according to an embodiment of the present disclosure.

[0040] Figure 15 and Figure 16 The figure illustrates a gap calibration process according to an embodiment of the present disclosure.

[0041] Figure 17 and Figure 18 The figure illustrates a gap calibration process according to an embodiment of the present disclosure.

[0042] Figure 19 and Figure 20 The figure illustrates a gap calibration process according to an embodiment of the present disclosure.

[0043] Figure 21 is a top view illustrating a moving path between a gap calibration area and a spraying area in a manufacturing apparatus for a display device according to an embodiment of the present disclosure.

[0044] Figure 22 is a cross-sectional view of a display device manufactured by the manufacturing apparatus for a display device according to an embodiment of the present disclosure.

[0045] Figure 23 yes Figure 22 A cross-sectional view of a display panel. DETAILED DESCRIPTION

[0046] The advantages and features of the present invention and the methods for implementing the same will become apparent by referring to the embodiments described in detail below and the accompanying drawings. However, the present invention is not limited to the embodiments disclosed herein, but can be implemented in various forms, and these embodiments are provided only to complete the disclosure of the present invention and to fully understand the scope of the present invention for those skilled in the art.

[0047] When an element or layer is referred to as being “on” another element or layer, it includes both the case where the element or layer is directly on top of the other element or layer and the case where the other element or layer is interposed therebetween. Like reference numerals refer to like parts throughout the specification.

[0048] Although terms such as "first" and "second" are used to describe various components, these components are not limited by these terms. These terms are only used to distinguish one component from another. Therefore, within the technical concept of the present invention, the first component can also be referred to as the second component.

[0049] The various features of the embodiments of the present invention may be combined or interchanged in part or in whole, and various technical interactions and operations are possible. These embodiments may be implemented independently of each other or in association with each other.

[0050] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings.

[0051] Figure 1 is a perspective view of a manufacturing apparatus 1 for a display device according to an embodiment, and Figure 2 The diagram shows Figure 1 1 is a top view of the substrate 21, the stage 20 and the gap measurement unit 100.

[0052] refer to Figure 1 and Figure 2 , the manufacturing apparatus 1 may include a base frame 10, a stage 20, a stage transfer unit, a dispenser 40, a dispenser support unit 50, a dispenser transfer unit, and a gap measurement unit 100. Here, the first direction DR1 and the second direction DR2 are orthogonal directions on the same plane, and the third direction DR3 is perpendicular to both the first direction DR1 and the second direction DR2.

[0053] The base frame 10 , which has a rectangular shape with long sides aligned in the first direction DR1 and a predetermined thickness in the third direction DR3 , may support the stage 20 and the stage transfer unit from below.

[0054] The stage 20 may be disposed on the base frame 10. The stage 20 may provide a space where a substrate 21 is disposed.

[0055] A substrate 21, which is a target object to be coated during the spraying process of the dispenser 40, may be placed on the upper surface of the stage 20. A substrate supporting unit (not shown) may be provided on the stage 20 and may fix the position of the substrate 21 on the stage 20.

[0056] The stage 20 may include a peripheral area A and a substrate seating area B where the substrate 21 is placed and ink is discharged onto the substrate 21 by the dispenser 40 .

[0057] The substrate seating area B is also an ejection process area where ink is discharged onto the substrate 21 during the ejection process, and thus may overlap with the substrate 21 during the ejection process.

[0058] The peripheral area A is disposed outside the spray process area. The peripheral area A may be adjacent to the substrate seating area B and may not overlap with the substrate 21 during the spray process.

[0059] The substrate seating area B and the peripheral area A may be formed in a single stage body. For example, a substrate seating portion may be provided in the central area of ​​the single stage body to define the substrate seating area B, and the peripheral area A may be defined in a predetermined space outside the substrate seating portion.

[0060] In some embodiments, the stage 20 may include a stage body including the substrate seating area B and an auxiliary frame constituting at least a portion of the surrounding area A, and the auxiliary frame may be coupled to one side of the stage body.

[0061] Hereinafter, an example will be described in which the stage 20 includes a stage body and an auxiliary frame, the auxiliary frame corresponds to the support frame 110 of the gap measurement unit 100, and the gap measurement process is performed on the support frame 110, but the present disclosure is not limited thereto. The gap measurement process may also be performed outside the substrate seating portion of the stage body.

[0062] The stage 20 may have the same planar shape as the substrate 21. For example, the stage 20 may have a rectangular, square, other polygonal, circular, or elliptical shape, and the present disclosure is not limited thereto. In an embodiment, the stage 20 may have a different shape from the substrate 21.

[0063] The stage 20 may be formed of a transparent or translucent material capable of transmitting light, or an opaque material capable of reflecting light.

[0064] The stage transfer unit may be coupled to the stage 20 and may move the stage 20 in the first direction DR1. The stage transfer unit may include a slide rail 31 and a stage driver 32 (see FIG. 1 ) that interacts with the slide rail 31 to provide a driving force for moving the stage 20. Figure 4 and Figure 5 ).

[0065] The slide rail 31 of the stage transfer unit is provided on the base frame 10, can be coupled to the lower surface of the stage 20, and can be provided in a first direction DR1. The stage driver 32 can be, but is not limited to, a drive motor, and can be any driving device capable of moving the stage 20. When the stage 20 moves, power is supplied to the stage driver 32, generating a driving force, which causes the stage 20 to move along the slide rail 31 in the first direction DR1. Therefore, during the blasting process or the gap measurement process, the stage 20 can reciprocate in the first direction DR1 between the substrate mounting area B and the surrounding area A.

[0066] The dispenser support unit 50 may include a vertical support member 51, a horizontal support member 52, and a dispenser support member 53, and may be coupled to one side of the base frame 10. For example, the dispenser support unit 50 may be fixedly coupled to the base frame 10, allowing it to perform a process while moving the stage 20. In an embodiment, the dispenser support unit 50 may be configured as a movable gantry, allowing it to perform a process while moving. However, the present disclosure is not limited to these examples.

[0067] The vertical support 51 of the dispenser support unit 50 may be fixedly or movably coupled to one side of the base frame 10 .

[0068] The horizontal support member 52 of the dispenser support unit 50 may be slidably coupled to the vertical support member 51 along the third direction DR3 , but the present disclosure is not limited thereto. In an embodiment, the horizontal support member 52 may be fixedly coupled to the vertical support member 51 .

[0069] At least one dispenser 40 may be mounted on a dispenser support 53 of the dispenser support unit 50. The dispenser support 53 may be fixedly or movably coupled to the horizontal support 52.

[0070] The dispenser transfer unit may include a dispenser vertical transfer portion that moves the dispenser 40 in a third direction DR3 that is a vertical direction.

[0071] The dispenser vertical transport section may be coupled to the dispenser support unit 50 on which the dispenser 40 is mounted, and thus may move the dispenser support unit 50 in the third direction DR3. The dispenser vertical transport section may include a vertical slide rail 54 and a dispenser vertical driver 60 (see FIG. 1 ) that interacts with the vertical slide rail 54 to provide a driving force for moving the dispenser 40 in the third direction DR3. Figure 4 and Figure 5 ).

[0072] Therefore, the dispenser 40 mounted on the dispenser support unit 50 can perform a spraying process by discharging the sealant onto the substrate 21 while being moved in the third direction DR3 by the dispenser vertical transfer portion. Specifically, since the horizontal support 52, the dispenser support 53, and the dispenser 40 are slidably coupled to the vertical rail 54 on the vertical support 51, the horizontal support 52, and the dispenser support 53, respectively, in response to power being supplied to the dispenser vertical driver 60 to supply a driving force, the horizontal support 52 can adjust the distance between the dispenser 40 and the substrate 21 placed on the stage 20 by raising and lowering the dispenser 40 while vertically moving along the vertical rail 54.

[0073] Here, the dispenser vertical transfer portion may include a vertical slide rail 54 formed in a vertical direction and a drive motor, or may include a hydraulic cylinder and a drive motor, but the present disclosure is not limited thereto. Various driving devices capable of vertically moving the dispenser 40 may be applicable to the dispenser vertical transfer portion.

[0074] A vertical slide rail 54 of the dispenser vertical transfer portion may be formed on the vertical support 51 of the dispenser support unit 50 and may guide the dispenser 40 to move in a direction indicated by a black double-headed arrow.

[0075] The dispenser vertical driver 60 of the dispenser vertical transport portion may be, but is not limited to, a drive motor. Various drive devices capable of vertically moving the dispenser 40 may be applicable to the dispenser vertical driver 60.

[0076] Therefore, when it is necessary to vertically move the dispenser 40, power can be supplied to the dispenser vertical driver 60, which can be a drive motor, to generate a driving force. This driving force can move the horizontal support member 52 connected to the dispenser support member 53 on which the dispenser 40 is mounted, along the vertical slide rail 54 on the vertical support member 51. As a result, the dispenser 40 can be moved vertically (i.e., in the third direction DR3). Therefore, the dispenser 40 can perform the ejection or gap measurement process while moving in the direction indicated by the double-headed arrow (i.e., in the third direction DR3).

[0077] The dispenser conveying unit has been described above as including a dispenser vertical conveying portion that moves the dispenser 40 in the third direction DR3. In some embodiments, the dispenser conveying unit may further include a dispenser horizontal conveying portion (not shown) that moves the dispenser 40 in the second direction DR2. For example, the dispenser horizontal conveying portion may include a horizontal slide rail (not shown) formed on the dispenser support 53 and to which the dispenser 40 is slidably coupled, and a horizontal drive motor that provides a driving force to move the dispenser 40 along the horizontal slide rail on the dispenser support 53.

[0078] Furthermore, the dispenser 40 has been described above as moving in the third direction DR3 via the dispenser transport unit, and the carrier 20 has been described above as moving in the first direction DR1. That is, by moving the carrier 20 in the first direction DR1 while the dispenser 40 is fixed in the first direction DR1, the relative position of the dispenser 40 and the carrier 20 can be changed. However, the present disclosure is not limited to this. In embodiments, the relative position of the dispenser 40 and the carrier 20 can be changed by moving the dispenser 40 in the first direction DR1 while the carrier 20 is fixed, or by moving both the carrier 20 and the dispenser 40 in the first direction DR1.

[0079] The dispenser 40 may discharge ink, and the ink may be provided in a liquid form. However, the present disclosure is not limited thereto.

[0080] In some embodiments, the ink may include, for example, a solvent and an organic material contained in the solvent. The organic material may be dispersed in the solvent. The organic material may be a solid substance remaining on the target substrate 21 after the solvent is removed. The solvent may be a substance that evaporates or volatilizes at room temperature or when heated. The solvent may be acetone, water, alcohol, toluene, etc. The ink may be dissolved in the solvent or may be a suspended solid. Here, the solid may be an organic material, a metallic material, etc. A sealant may be used as the ink, but the present disclosure is not limited thereto. The various types of inks described above may also be used.

[0081] The dispenser 40 may spray, for example, a sealant and may include a nozzle 41 (see FIG. 4 ) that receives the sealant from a separate storage container (not shown) and discharges it onto the substrate 21. Figures 8 to 18). The sealant can be supplied to the nozzle 41 from an external source, or can be supplied from an internal storage container within the dispenser 40 and discharged through the nozzle 41. The sealant can be an exemplary liquid sprayed through the nozzle 41, but the present disclosure is not limited thereto. That is, various other liquids, such as liquid crystals or solutions for forming organic films, can also be used. Here, the dispenser 40 can be moved in the up and down directions by a dispenser conveying unit connected to the dispenser support unit 50, or can be mounted on the dispenser support 53 to be movable in the up and down directions (i.e., in the third direction DR3). In an embodiment, a dispenser motor (not shown) can be provided separately to lift the dispenser 40, or only the nozzle 41 can be lifted.

[0082] Still refer to Figure 1 and Figure 2 The gap measuring unit 100 is provided in a gap calibration area (which is a surrounding area A) on one side of the stage 20 (i.e., on a moving path of the stage 20), and can calibrate a gap G between the dispenser 40 and a reference block 120 to be described later (see FIG. Figure 11 Here, calibration means adjustment to a specific or set standard, and calibration of the gap G may be performed before or during the spraying process of discharging the sealant onto the substrate 21 .

[0083] The gap measuring unit 100 may include a supporting frame 110 fixed to one side of the base frame 10 , a reference block 120 mounted on the supporting frame 110 , and a measuring camera 130 disposed adjacent to the reference block 120 and measuring the gap G.

[0084] The support frame 110 may be integrally formed with the base frame 10, or may be provided as a separate frame to which the base frame 10 is coupled. In addition, the support frame 110 may be fixed to the base frame 10, or may be installed to be raised and lowered relative to the base frame 10 in the third direction DR3.

[0085] The support frame 110 may be disposed at an end portion of the base frame 10 along a first direction DR1 that is a moving direction of the stage 20. The upper surface 111 (see FIG. 1 ) of the support frame 110 may be provided at an end portion of the base frame 10 along a first direction DR1 that is a moving direction of the stage 20. Figure 10 ) may be arranged in the same plane as the upper surface of the base frame 10, so that the thickness of the support frame 110 in the third direction DR3 is the same as the thickness of the base frame 10 in the third direction DR3. However, the present disclosure is not limited to this. In an embodiment, the upper surface 111 of the support frame 110 and the upper surface of the base frame 10 may not be in the same plane, but may be arranged with a step difference. In addition, the upper surface 111 of the support frame 110 may be arranged in the same plane as the upper surface of the stage 20, or the upper surface 111 of the support frame 110 and the upper surface of the stage 20 may be arranged with a step difference.

[0086] The reference block 120 can be aligned with a reference point, ie, a zero point, so that the measurement camera 130 can measure the gap G. The upper surface 121 (see FIG. Figures 11 to 16 ) is used as a reference plane to allow the measurement camera 130 to measure the gap G.

[0087] The upper surface 121 of the reference block 120 may form a flat plane along the first direction DR1 together with the upper surface of the substrate 21. In an embodiment, if the reference block 120 has a lower height than the substrate 21, the reference block 120 may be disposed with a step difference relative to the upper surface of the substrate 21.

[0088] The measurement camera 130 is used to measure the distance between the reference plane and the tip 42 (see Figure 9 ), the tip 42 is the end of the nozzle 41. To measure this gap, the height from the upper surface 121 of the reference block 120 to the tip 42 of the nozzle 41 can be measured using the upper surface 121 of the reference block 120 as a reference point and as a zero point. In addition, the measurement camera 130 can further include a separate laser displacement sensor to measure the gap G together with the measurement camera 130. The laser displacement sensor can include a light emitting portion that outputs distance measurement laser light to the substrate 21 and a receiving portion that receives the laser light output from the light emitting portion, thereby allowing the distance between the substrate 21 and the nozzle 41 to be measured.

[0089] Figure 3 is a top view of a manufacturing apparatus 1 for a display device according to an embodiment of the present disclosure.

[0090] Figure 3 Manufacturing equipment 1 and Figure 2 The difference from the corresponding part is that the gap measurement unit 100 includes a plurality of measurement cameras 130 .

[0091] and Figure 2 The gap measurement unit 100 is equipped with a reference block 120 and a measurement camera 130. Figure 3 The gap measurement unit 100 may be equipped with a long reference block 120_1 and a plurality of measurement cameras 130 arranged along the length direction of the reference block 120_1 , but the present disclosure is not limited thereto. In an embodiment, the gap measurement unit 100 may include a plurality of reference blocks 120 and a plurality of corresponding measurement cameras 130 .

[0092] Figure 4 is a block diagram of a manufacturing apparatus 1 for a display device according to an embodiment of the present disclosure.

[0093] refer to Figure 4The manufacturing apparatus 1 may further include a storage unit 70 storing a driving value of the dispenser vertical driver 60 based on the gap measurement result from the measurement camera 130 and a control unit 80 controlling the dispenser vertical driver 60 to raise or lower the dispenser 40 .

[0094] The storage unit 70 stores drive values ​​for the dispenser vertical driver 60. For example, if the dispenser vertical driver 60 is a drive motor, the dispenser vertical driver 60 can raise or lower the dispenser 40 under the control of the control unit 80, thereby raising the nozzle 41 of the dispenser 40 away from the substrate 21 or lowering the nozzle 41 toward the substrate 21. The storage unit 70 can store encoder values ​​from the drive motor that is the dispenser vertical driver 60. The encoder values ​​can be position, angle, or speed measurement values, or control values ​​for the speed or rotation amount of the drive motor.

[0095] Based on the gap measurements from the measurement camera 130 , the encoder values ​​from the dispenser vertical driver 60 may be stored directly in the storage unit 70 .

[0096] When the dispenser 40 reaches the gap measurement unit 100 , the control unit 80 may lower the dispenser 40 through the dispenser vertical driver 60 and may store an encoder value of the dispenser vertical driver 60 in the storage unit 70 based on the gap measurement result from the measurement camera 130 .

[0097] If the gap measurement result indicates that the gap G matches the reference setting value, the control unit 80 may store the driving value of the dispenser vertical driver 60 in the storage unit 70. The control unit 80 may move the dispenser 40 from the gap calibration area A to the substrate seating area B, which is the spraying area.

[0098] Figure 5 is a block diagram of a manufacturing apparatus 1 for a display device according to an embodiment of the present disclosure.

[0099] refer to Figure 5 The manufacturing apparatus 1 may further include a storage unit 70 for storing a driving value of the dispenser vertical driver 60 based on a gap measurement result from the measurement camera 130, a lookup table 90 for saving various driving values ​​of the dispenser vertical driver 60 as data values, and a control unit 80-1 for controlling the dispenser vertical driver 60 to raise or lower the dispenser 40.

[0100] Figure 5 Manufacturing equipment 1 and Figure 4 is identical to its counterpart except that it further includes a lookup table 90 .

[0101] Specifically, based on the gap measurement results from the measurement camera 130, the encoder value from the dispenser vertical driver 60 can be easily stored in the storage unit 70, such as Figure 4 In the embodiment, as shown in Figure 5 As shown in , a separate lookup table may be additionally provided. Here, the lookup table 90, which is a table of frequently used data values, may include driving values ​​(ie, encoder values ​​or data values) of the dispenser vertical driver 60 corresponding to the gap measurement results.

[0102] Figure 6 is a flowchart illustrating a gap calibration method of the manufacturing apparatus 1 for a display device according to an embodiment of the present disclosure.

[0103] refer to Figure 6 The gap calibration method includes: placing a dispenser 40 above the substrate 21 (step S110); moving the stage 20 on which the substrate 21 is placed to place the dispenser 40 in the gap calibration area A (step S120); lowering the dispenser 40 to set the tip 42 of the nozzle 41 of the dispenser 40 between the reference block 120 and the measuring camera 130 (step S130); measuring the gap between the tip 42 of the nozzle 41 and the reference block 120 (step S140); based on the measurement result of the gap, storing the encoder value and raising the dispenser 40 (step S150), for example, if the measured gap matches the predetermined value, storing the corresponding encoder value and moving the dispenser 40 upward; and moving the stage 20 to move the dispenser 40 away from the gap calibration area A (step S160).

[0104] In this way, if the gap measurement result indicates that the measured gap matches the reference set value, the driving value of the dispenser vertical driver 60 can be stored in the storage unit 70, and the dispenser 40 can be easily moved from the gap calibration area A to the ejection area B.

[0105] Figure 7 is a flowchart illustrating a gap calibration method of the manufacturing apparatus 1 for a display device according to an embodiment of the present disclosure.

[0106] refer to Figure 7The gap calibration method includes: placing a dispenser 40 above the substrate 21 (step S110_1); moving the stage 20 on which the substrate 21 is placed to place the dispenser 40 in the gap calibration area A (step S120_1); lowering the dispenser 40 to set the tip 42 of the nozzle 41 of the dispenser 40 between the reference block 120 and the measuring camera 130 (step S130_1); measuring the gap between the tip 42 of the nozzle 41 and the reference block 120 (step S140_1); if the measured gap does not match a predetermined value (e.g., a reference set value), adjusting the gap to a predetermined value by raising or lowering the dispenser 40, storing the corresponding encoder value, and then moving the dispenser 40 upward (step S150_1); and moving the stage 20 to move the dispenser 40 away from the gap calibration area A (step S160_1).

[0107] In this manner, if the gap measurement result indicates that the measured gap does not match the predetermined value, for example, if the measured gap is less than the reference set value, the dispenser 40 can be raised to adjust the gap, and if the measured gap is greater than the reference set value, the dispenser 40 can be lowered to adjust the gap. Thereafter, the encoder value can be stored, and the dispenser 40 can be moved away from the gap calibration area A.

[0108] The following will refer to Figures 8 to 18 The above-mentioned gap calibration method is described in further detail.

[0109] Figures 8 to 14 The figure illustrates a gap calibration process according to an embodiment of the present disclosure.

[0110] refer to Figure 8 , with the dispenser 40 placed above the substrate 21, the stage 20 can be moved from its initial position corresponding to the substrate placement area B in the direction indicated by the one-way arrow. Figure 9 As shown in FIG, the dispenser 40 may be disposed in the gap calibration area A where the gap measurement unit 100 is disposed.

[0111] refer to Figure 9 , when the dispenser 40 reaches the gap calibration area A, the nozzle 41 of the dispenser 40 is disposed between the reference block 120 and the measurement camera 130 .

[0112] refer to Figure 10 , by lowering the dispenser 40 in the gap calibration area A, the nozzle 41 of the dispenser 40 may be disposed between the measurement camera 130 and the reference block 120 , and the gap G may be measured.

[0113] refer to Figure 11If the gap G measured by the measuring camera 130 based on the upper surface 121 of the reference block 120 is the same as the previously set reference value, the control unit 80 may store the corresponding encoder value of the dispenser vertical driver 60 in the storage unit 70. For example, referring to Figure 12 If the reference set value is zero and the measured gap is actually zero, meaning that there is no gap between the reference block 120 and the dispenser 40, the encoder value of the dispenser vertical driver 60 that has lowered the dispenser 40 can be stored in the storage unit 70.

[0114] refer to Figure 13 , the distributor 40 can be raised by the vertical conveyor portion of the distributor. Figure 14 , the stage 20 may be moved by the stage transfer unit to move the dispenser 40 away from the gap calibration area A.

[0115] refer to Figure 21 , the dispenser 40 , which has exited the gap calibration area A, may discharge the sealant onto the substrate 21 , thereby coating the sealant along an edge area of ​​the substrate 21 .

[0116] In this way, since the position correction of the dispenser 40 is performed based on the precisely set gap value and the dispenser 40 moves toward the substrate 21, the dispenser 40 can correctly eject the sealant with the gap between it and the substrate 21 fixed, which ensures a stable discharge amount and a consistent line width. Even if the dispenser 40 is raised to eject the sealant, the gap between the dispenser 40 and the substrate 21 can be accurately corrected, which allows the discharge amount of the sealant to be determined based on the stored encoder value during gap calibration.

[0117] In a contact-type gap measurement method in which the nozzle 41 directly contacts the surface of the substrate 21 to measure the gap therebetween, the nozzle 41 may have a free end, and therefore, each contact angle may vary each time the nozzle 41 contacts the substrate 21, thereby causing gap calibration errors and reducing the reproducibility of the gap measurement. In contrast, in a non-contact gap calibration method according to an embodiment of the present disclosure, the gap measurement unit 100 is provided in a non-contact manner, thereby preventing changes in the contact angle during measurement and avoiding damage to the nozzle 41. In addition, accurate gap calibration allows for stable discharge volume settings and can provide accurate line widths based on accurate gap data.

[0118] Furthermore, since the gap measurement can be performed in the gap calibration area A (which is an area that does not overlap with the substrate 21), the gap measurement can be performed not only before and after the ink is ejected onto the substrate 21, but also during the ejection of the ink onto the substrate 21. This allows the gap measurement to be performed using the reference block 120 even when there is no substrate 21, and during the ejection of the ink onto the substrate 21, the gap measurement can be performed in the gap calibration area A outside the ejection area on the substrate 21.

[0119] Figure 15 and Figure 16 The figure illustrates a gap calibration process according to an embodiment of the present disclosure.

[0120] Figure 15 and Figure 16 Examples and Figures 8 to 14 Specifically, if the gap measured in the gap calibration area A deviates from the reference set value, especially if the measured gap is smaller than the reference set value, such as Figure 15 As shown in , the distributor 40 can be raised to adjust the gap G to the reference setting value. On the contrary, if the measured gap is greater than the reference setting value, as shown in Figure 16 As shown in , the dispenser 40 can be lowered to adjust the gap G to the reference set value. Subsequently, the control unit 80 stores the corresponding encoder value of the dispenser vertical driver 60 in the storage unit 70, and the stage transfer unit moves the stage 20 to place the dispenser 40 outside the gap calibration area A.

[0121] Figure 17 and 18 The figure illustrates a gap calibration process according to an embodiment of the present disclosure.

[0122] Figure 17 and Figure 18 Examples and Figures 8 to 14 The embodiment is almost the same as that of FIG. 1 , except that the height from the upper surface 111 of the support frame 110 to the upper surface of the reference block 120_2 is greater than the height from the upper surface 111 of the support frame 110 to the upper surface of the substrate 21.

[0123] Figure 19 and Figure 20 The figure illustrates a gap calibration process according to an embodiment of the present disclosure.

[0124] Figure 19 and Figure 20 Examples and Figures 8 to 14 The embodiment is almost the same, except that Figure 19The thickness of the support frame 110_1 shown in FIG is less than that of the loading platform 20, and the support frame 110_1 is coupled to be height-adjustable relative to the loading platform 20. Here, a hydraulic cylinder and a motor can be provided as a height adjustment device to couple the support frame 110 to be height-adjustable, or a slide rail and a receiving groove for accommodating the slide rail can be provided to allow sliding movement. However, the present disclosure is not limited to these embodiments.

[0125] refer to Figure 19 and Figure 20 When the substrate 21 is placed on the stage 20 , the support frame 110_1 can be raised by the height adjustment device so that the upper surface of the substrate 21 and the upper surface of the reference block 120 can be in the same plane.

[0126] Hereinafter, a display device manufactured by the manufacturing apparatus 1 for a display device according to an embodiment of the present disclosure will be described.

[0127] Figure 21 is a top view illustrating a movement path between a gap calibration area A and a spraying area B (sometimes referred to as a substrate placement area B) in a manufacturing apparatus 1 for a display device according to an embodiment of the present disclosure, Figure 22 is a cross-sectional view of a display device manufactured by the manufacturing apparatus 1, and Figure 23 yes Figure 22 sectional view of the display panel 300.

[0128] refer to Figure 21 , the dispenser 40 disposed above the substrate 21 moves along the illustrated path to perform gap measurement in the gap calibration area A where the gap measurement unit 100 is disposed. Thereafter, the dispenser 40 moves to the spraying area B to apply the sealant 22 to the substrate 21 in the shape of a rectangular frame along the edge of the substrate 21.

[0129] refer to Figure 22 , another structure 21_1 is laminated on the substrate 21 using the sealant 22 coated on the substrate 21 in the shape of a rectangular frame to manufacture a display device including the display panel 300 .

[0130] refer to Figure 23 The display panel 300 may include a substrate 21 , a driving layer 320 , a light emitting element layer 330 , and an encapsulation layer (not shown).

[0131] The substrate 21 provides space for the drive layer 320, the light-emitting element layer 330, and the encapsulation layer. The substrate 21 can be a flexible substrate formed of a flexible polymer material. For example, the substrate 21 can be formed of a flexible plastic such as polyimide, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polyarylate, polyetherimide, polyethersulfone, etc. In an embodiment, the substrate 21 can be a rigid substrate such as a glass substrate, a semiconductor substrate, or a quartz substrate.

[0132] The driving layer 320 includes elements for providing signals to the light emitting element layer 330. The driving layer 320 may include various signal lines, such as scan lines (not shown), data lines (not shown), power lines (not shown), and emission lines (not shown). The driving layer 320 may include a plurality of transistors and a plurality of capacitors. The transistors may include a switching transistor (not shown) and a driving transistor Qd provided in each pixel (not shown).

[0133] The driving transistor Qd includes an active layer 321 , a gate electrode 322 , a source electrode 335 , and a drain electrode 323 .

[0134] The driving layer 320 may further include a first insulating film 333 disposed on the active layer 321 , and the gate electrode 322 may be provided on the first insulating film 333 .

[0135] The driving layer 320 may further include a second insulating film 334 disposed on the gate electrode 322. A source electrode 335 and a drain electrode 323 may be disposed on the second insulating film 334.

[0136] The source electrode 335 and the drain electrode 323 may be connected to the active layer 321 through contact holes CH1 and CH2 provided in the first insulating film 333 and the second insulating film 334, respectively. The source electrode 335 and the drain electrode 323 may be formed as a metal multilayer structure of titanium (Ti) / aluminum (Al) / titanium (Ti), but the present disclosure is not limited thereto.

[0137] The driving layer 320 may further include a protection film 336 disposed on the source electrode 335 and the drain electrode 323 .

[0138] The light emitting element layer 330 may include a light emitting element LD, and the light emitting element LD may include a first electrode AE, an organic layer OL, and a second electrode CE.

[0139] The first electrode AE ​​is disposed on the protective film 336 , and the first electrode AE ​​is connected to the drain electrode 323 through a contact hole CH3 formed in the protective film 336 .

[0140] The light emitting element layer 330 may further include a pixel defining layer PDL disposed on the protective film 336. The pixel defining layer PDL extends to the first electrode AE ​​and includes an opening exposing the first electrode AE, and may define an emission area LTA in a plan view.

[0141] Therefore, by performing non-contact gap calibration before or during the ejection process, the accuracy of the discharge amount can be ensured, thereby enabling a display device having a specified line width to be formed through a stable process.

[0142] At the end of the detailed description, it will be appreciated by those skilled in the art that many changes and modifications may be made to the embodiments without substantially departing from the principles of the inventive concept. Therefore, the disclosed embodiments of the inventive concept are used only in a general and descriptive sense and not for the purpose of limitation.

Claims

1. A manufacturing apparatus for a display device, comprising: a stage including a substrate placement area and a peripheral area provided around the substrate placement area, the substrate placement area being configured to place a substrate; a dispenser disposed above the stage and including a nozzle for discharging ink; as well as a gap measurement unit, at least partially arranged in the surrounding area of ​​the stage, The gap measurement unit includes a reference block and a camera facing the reference block.

2. The manufacturing apparatus according to claim 1, wherein The loading platform includes: The stage body includes the substrate placement area; and An auxiliary frame is provided on one side of the stage body, and The gap measurement unit is arranged to overlap with the auxiliary frame.

3. The manufacturing equipment according to claim 1, wherein An upper surface of the reference block and an upper surface of the substrate are arranged in the same plane.

4. The manufacturing apparatus according to claim 1, further comprising: a dispenser vertical driver to move the dispenser vertically relative to the substrate and the reference block, Wherein, in the surrounding area, the dispenser is vertically raised or lowered between the reference block and the camera by the dispenser vertical driver.

5. The manufacturing apparatus according to claim 4, further comprising: a storage unit that stores a drive value of the dispenser vertical driver based on the gap measurement result from the camera; as well as A control unit controls the dispenser vertical drive to raise and lower the dispenser.

6. The manufacturing apparatus according to claim 5, wherein if the measurement result indicates that the gap matches a reference set value, the control unit stores the driving value of the dispenser vertical driver in the storage unit and moves the dispenser in the surrounding area to the substrate placement area.

7. The manufacturing apparatus according to claim 5, further comprising: A lookup table stores the drive value of the dispenser vertical driver as a data value.

8. The manufacturing apparatus according to any one of claims 2 to 7, further comprising: A height adjustment device connects the auxiliary frame to be adjustable in height relative to the loading platform body.

9. The manufacturing apparatus according to any one of claims 2 to 7, wherein The reference block is arranged on the auxiliary frame at a position spaced apart from the substrate in a first direction, and The camera is positioned behind the reference block in the first direction.

10. The manufacturing apparatus according to claim 1, further comprising: A base frame supporting the loading platform from below; a stage transport unit, for moving the stage along a first direction; as well as a dispenser support unit, coupling the dispenser to the base frame, The reference block has a strip shape along a second direction perpendicular to the first direction, and a plurality of cameras including the camera are provided along the second direction.

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