Adhesive Layer Jetting and UV Curing for Continuous Panel Throughput
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Solution Overview
Problem
Conventional display device manufacturing systems face inefficiencies due to discontinuous processes, requiring movement between process regions, leading to decreased productivity and increased costs, particularly in adhesive layer formation and UV curing processes.
Innovation Solution
A display device manufacturing system with an adhesive layer forming apparatus that includes multiple support chucks, gantries for heads and UV curing systems, and controllers to manage panel movement and adhesive application, allowing simultaneous and sequential adhesive layer formation and curing across multiple panels without positional repositioning, enhancing spatial intensity and throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single head and single UV curing system are used to form adhesive layers, then device complexity is reduced, but productivity decreases due to sequential processing and waiting times
Solution Approach 1:
The adhesive layer forming apparatus is divided into multiple independent adhesive layer forming parts, each equipped with its own head and UV curing system. This segmentation allows parallel processing of multiple panels simultaneously, eliminating waiting times and significantly improving manufacturing throughput while maintaining manageable complexity through modular design
Solution Approach 2:
Multiple adhesive layer forming parts are integrated into a single apparatus that shares common infrastructure such as the panel support chuck and control system. This merging approach enables simultaneous adhesive layer formation on multiple panels while reducing overall system complexity compared to having completely separate systems for each panel
2Productivity
If panels are moved between process regions for adhesive formation and curing, then process flexibility is improved, but process efficiency decreases due to discontinuous operations
Solution Approach 1:
The adhesive layer forming part and UV curing system are integrated into a single apparatus that processes multiple panels simultaneously. By providing multiple adhesive layer forming parts within the same apparatus, the system enables continuous processing without requiring panels to be moved between separate process regions, thereby improving process efficiency while maintaining operational flexibility
Solution Approach 2:
The apparatus is designed to perform adhesive layer formation and UV curing in a continuous manner across multiple panels. While one panel is being cured, another panel can have its adhesive layer formed, eliminating idle time and ensuring continuous productive action throughout the manufacturing process
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 system improves process efficiency and productivity by enabling simultaneous adhesive layer formation and curing across multiple panels, reducing waiting times and increasing manufacturing throughput and spatial intensity.
Implementation Method 1
a first head, which faces the first support chuck and the second support chuck, in the second direction on the first support chuck and the second support chuck and forms an adhesive layer on any one of the first panel and the second panel by jetting
Implementation Method 2
a third gantry configured to move an ultraviolet (UV) curing system, which temporarily cures the adhesive layer on the first panel or the second panel
Data Source
AI summary
Disclosed are an adhesive layer forming apparatus and a display device manufacturing system including the same. The adhesive layer forming apparatus includes a first support chuck configured to move a first panel along a panel movement path in a first direction, a second support chuck provided side by side with the first support chuck in a second direction orthogonal to the first direction and configured to move a second panel along a panel movement path, and a first gantry configured to move a first head, which faces the first support chuck and the second support chuck, in the second direction on the first support chuck and the second support chuck and forms an adhesive layer on any one of the first panel and the second panel by jetting.