Display Device Sealant Dispenser With Optical Gap Calibration
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Solution Overview
Problem
Inaccurate gap calibration between the substrate and the nozzle during the application of sealant in display device manufacturing leads to variations in discharge amount, causing inconsistencies in linewidth and application quality.
Innovation Solution
A manufacturing apparatus and method that performs gap calibration in a non-contact manner using a reference block and camera to measure and adjust the gap between the nozzle and the substrate, employing a dispenser vertical driver and control unit to ensure precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact-based gap calibration is used, then measurement can be performed, but it causes damage to the nozzle and reduces measurement precision
Solution Approach 1:
The patent replaces the mechanical contact-based gap calibration method with an optical measurement system. A camera captures images of the substrate and nozzle, and image processing algorithms calculate the gap distance non-contactually, eliminating mechanical wear and damage while maintaining measurement precision.
Solution Approach 2:
The patent introduces an optical intermediary (camera and image processing system) between the measurement object (gap between nozzle and substrate) and the measurement process. This intermediary enables indirect measurement without physical contact, resolving the contradiction between measurement accuracy and nozzle protection.
2Ease of manufacture
If manual gap calibration is performed, then the process is simple, but it causes process dispersion and reduces manufacturing precision
Solution Approach 1:
The patent implements an automated feedback-based calibration system where the camera continuously monitors the gap between nozzle and substrate, and the system automatically adjusts parameters based on captured images. This eliminates manual intervention variability while maintaining operational simplicity, thereby improving manufacturing precision without sacrificing ease of manufacture.
Solution Approach 2:
The system performs self-calibration by automatically capturing images, processing them to determine gap distances, and adjusting parameters without external intervention. This automated self-service approach eliminates human error in manual calibration while keeping the process simple and repeatable.
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
Enables accurate and reproducible gap calibration, ensuring stable discharge volume and consistent linewidths in the application of sealant, thereby improving the manufacturing process of display devices.
Implementation Method 1
a gap measurement unit positioned at least partially in the surrounding area of the stage. The gap measurement unit includes a reference block and a camera that faces the reference block
Data Source
AI summary
The present disclosure relates to a manufacturing apparatus and method for a display device. According to an embodiment of the disclosure, a manufacturing apparatus for a display device comprises: a stage including a substrate seating area, which is configured for seating a substrate, and a surrounding area, which is positioned around the substrate seating area; a dispenser positioned above the stage and including a nozzle for discharging ink; and a gap measurement unit positioned at least partially in the surrounding area of the stage. The gap measurement unit includes a reference block and a camera that faces the reference block.