Display Encapsulation Repair for Uniform Inorganic Layer Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of display devices is hindered by impurities and grooves in the organic layer, which can damage the inorganic layer and reduce the yield rate, leading to defective products.
Innovation Solution
An apparatus and method that includes a mounting unit, inspection unit, and repair unit to detect and correct defects in the organic encapsulation layer, ensuring a uniform inorganic layer formation by supplying organic material to adjust taper angles or remove protruding impurities and grooves, thereby preventing damage to the inorganic layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the organic encapsulation layer is formed without inspection and repair, then the manufacturing process is simple and fast, but impurities and grooves occur in the organic layer causing defects
Solution Approach 1:
The inspection unit detects defects in the organic encapsulation layer before the inorganic layer is formed, and the repair unit removes protruding portions or supplies organic material to adjust taper angles in advance. This preliminary detection and repair prevents defects from propagating to subsequent layers, ensuring high manufacturing precision without requiring complete process rework.
Solution Approach 2:
The repair unit acts as an intermediary between the inspection unit and the inorganic layer formation process. It receives defect information from the inspection unit and performs targeted repairs by removing protruding portions or supplying organic material, thereby mediating the transition from defective to defect-free organic encapsulation layer before inorganic layer deposition.
2Manufacturing precision
If protruding portions of impurities are removed, then the inorganic layer can be formed uniformly, but the manufacturing process time increases
Solution Approach 1:
The inspection and repair operations are performed on the organic encapsulation layer before the inorganic layer is formed. By removing protruding portions and adjusting taper angles in advance, the surface is prepared for uniform inorganic layer deposition, preventing the need for time-consuming rework after inorganic layer formation.
Solution Approach 2:
The repair unit performs localized repairs only at defective portions of the organic encapsulation layer rather than reprocessing the entire layer. It selectively removes protruding portions or supplies organic material to specific areas with defects, minimizing the impact on overall manufacturing time while ensuring local uniformity for inorganic layer formation.
3Reliability
If the organic layer is not repaired before forming the inorganic layer, then the production speed is high, but the inorganic layer gets damaged or shielding effect is rendered ineffectual
Solution Approach 1:
The inspection unit detects protruding portions and grooves in the organic encapsulation layer before the inorganic layer is formed. The repair unit then removes protruding portions or supplies organic material to adjust taper angles, preparing a suitable surface in advance. This prevents damage to the inorganic layer during formation and ensures effective shielding, thereby maintaining high manufacturing yield rate.
Solution Approach 2:
The repair unit performs preliminary anti-action by removing protruding portions that could cause damage to the inorganic layer and by adjusting taper angles to prevent future damage. This preemptive repair eliminates the root causes of potential inorganic layer damage before the inorganic layer is deposited, ensuring both reliability and productivity.
Data Source
AI summary
An apparatus for manufacturing a display device and a method of manufacturing the display device are provided. The apparatus for manufacturing the display device includes: a mounting unit, on which a display substrate may be arranged; an inspection unit movably arranged on the mounting unit and configured to inspect whether or not an organic encapsulation layer of the display substrate is defective; and a repair unit movably arranged on the mounting unit and configured to supply an organic material to a defective portion of the organic encapsulation layer, or to remove at least a portion of the defective portion of the organic encapsulation layer.