Display Manufacturing Ink Mixing and Counting for Uniform Pixel Filling
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Solution Overview
Problem
Existing display device manufacturing processes face challenges in reducing process costs and ensuring uniform distribution of light emitting elements in pixels.
Innovation Solution
A display device manufacturing apparatus is designed with a first and second reservoir, a mix chamber, and channels connected by a counter and open and close unit, allowing precise control of light emitting element distribution using a controller and movement inducement units to ensure uniform dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light emitting elements are dispensed without precise control, then manufacturing process is simpler and faster, but uniform distribution of light emitting elements in pixels cannot be ensured
Solution Approach 1:
The apparatus is divided into functionally independent modules: a first reservoir for solvent, a second reservoir for light emitting elements, a mix chamber for combining them, and a counter for monitoring element quantity. This segmentation allows each module to perform its specific function efficiently while maintaining overall system precision for uniform pixel filling.
Solution Approach 2:
A counter is integrated into the system to monitor and provide feedback on the number of light emitting elements dispensed. This feedback mechanism enables real-time verification of element distribution, ensuring uniform pixel filling by tracking whether the target number of elements has been achieved, and prevents both under-filling and over-filling conditions.
2Manufacturing precision
If precise control of light emitting element amount is implemented, then uniform distribution in pixels is ensured, but process cost increases
Solution Approach 1:
The counter automatically monitors and counts the light emitting elements as they are dispensed, eliminating the need for manual verification processes. This self-service capability provides precise control over element distribution while reducing labor costs and increasing manufacturing efficiency, thereby offsetting the added apparatus cost through operational savings.
Solution Approach 2:
The system allows dynamic adjustment of dispensing parameters such as the target number of elements per pixel, flow rates, and timing. By optimizing these parameters, the system achieves precise control with minimal material waste and rework, reducing overall process costs while maintaining high manufacturing precision.
3Productivity
If light emitting elements are not uniformly distributed, then manufacturing is simpler, but pixel quality and display performance deteriorate
Solution Approach 1:
The system performs preliminary actions by pre-configuring the first and second reservoirs, establishing the ink composition in advance, and setting the target element count before actual pixel filling begins. This preliminary preparation ensures that when manufacturing proceeds, uniform distribution can be maintained consistently across all pixels, preserving both productivity and reliability.
Solution Approach 2:
The counter continuously monitors element distribution and provides feedback during the manufacturing process. This real-time monitoring ensures that uniform distribution is maintained, preventing quality deterioration while allowing high-speed manufacturing to proceed without frequent inspections or corrections.
Data Source
AI summary
A display device manufacturing apparatus includes a first reservoir accommodating a solvent; a second reservoir accommodating a light emitting element; a mix chamber accommodating an ink including the solvent and the light emitting element ; a first channel connecting the first reservoir and the mix chamber; a second channel connecting the second reservoir and the mix chamber; and a counter that obtains information on a number of the light emitting elements that are moved in the second channel.