Display Droplet Deposition Control for Pixel Alignment Accuracy
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Solution Overview
Problem
The challenge in manufacturing display devices with bent structures is accurately applying droplets to pixel patterns, which affects the quality of the display due to inaccuracies in supplying droplets to the pixel defining layer.
Innovation Solution
An apparatus with multiple head portions and a controller that adjusts the location and timing of droplet discharge from nozzles to accurately position and apply droplets on a processing substrate, allowing for precise control over the placement and quantity of droplets on pixel areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If droplets are supplied to pixel defining layer openings, then organic emission layer is formed, but droplet placement accuracy deteriorates due to mechanical errors in positioning
Solution Approach 1:
The system measures the actual positions of pixels and head portions using sensing units, calculates position differences, and compensates for these differences by adjusting droplet ejection timing and head portion locations. This closed-loop feedback mechanism ensures accurate droplet placement despite mechanical positioning errors, directly resolving the contradiction between manufacturing precision and reliability.
2Productivity
If multiple head portions are used to supply droplets, then manufacturing efficiency is improved, but control complexity increases
Solution Approach 1:
The system divides the manufacturing task into multiple independent head portions, each capable of supplying droplets to different pixel regions. Each head portion is controlled independently with its own position and timing adjustments, allowing parallel processing that improves productivity while managing complexity through modular control.
Solution Approach 2:
The system dynamically adjusts the operation of multiple head portions based on real-time position measurements. The controller coordinates droplet ejection timing and head portion locations dynamically, allowing the system to adapt to mechanical variations and maintain precision across multiple simultaneous operations.
3Speed
If droplet ejection timing is synchronized, then manufacturing speed is improved, but positioning accuracy deteriorates due to mechanical variations
Solution Approach 1:
The system performs preliminary measurements of pixel and head portion positions before droplet ejection. Based on these pre-measured positions, the controller calculates and applies compensation values for timing and location adjustments. This preliminary action allows the system to maintain both high speed and high precision by pre-planning droplet ejection parameters.
Data Source
AI summary
An apparatus includes a plurality of head portions which supplies droplets on a processing substrate, and a controller which applies a signal to each of the head portions, where the controller controls each of the head portions to supply the droplets on the processing substrate, where the signal includes a difference between a preset location of a pixel and an actual location of a pixel.