Display Layer Deposition Source Layout for Uniform Refractive Index
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Solution Overview
Problem
Existing manufacturing processes for display devices are inefficient, leading to high costs and material wastage due to the complexity of layer deposition, particularly in flexible and bendable display devices.
Innovation Solution
A manufacturing apparatus with a chamber and deposition sources that sequentially deposit multiple layers on a display substrate by moving in alternating directions, using first and second deposition parts to control the concentration and refractive index of layers, reducing material wastage and enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple deposition sources are used to deposit different materials sequentially, then the layer structure quality is improved, but the manufacturing time and process complexity increase
Solution Approach 1:
Multiple deposition sources (first deposition source, second deposition source, third deposition source) are merged into a single integrated deposition apparatus, allowing simultaneous or sequential deposition of different materials without requiring separate processing steps, thereby reducing manufacturing time while maintaining layer structure quality
Solution Approach 2:
The deposition sources are configured to be movable or adjustable, allowing dynamic control over deposition positions and sequences. This enables flexible deposition patterns where materials can be deposited in optimized sequences, reducing total manufacturing time while achieving precise layer structures
2Manufacturing precision
If deposition sources move in alternating directions to deposit layers, then material distribution uniformity is improved, but the device complexity increases
Solution Approach 1:
The deposition process is segmented into multiple directional passes (first direction and second direction), with each deposition source responsible for specific material deposition in alternating directions. This segmentation achieves uniform material distribution while keeping each individual deposition source relatively simple in structure
Solution Approach 2:
The deposition sources perform periodic alternating directional movements, depositing materials in a rhythmic sequence. This periodic action ensures uniform material distribution across the substrate while using simple reciprocating motion mechanisms rather than complex positioning systems
3Manufacturing precision
If the deposition source covers overlapping areas multiple times, then complete layer coverage is achieved, but material piling up increases
Solution Approach 1:
Different deposition sources deposit materials with locally optimized characteristics. The first, second, and third deposition sources deposit different materials (first, second, and third deposition materials respectively) with controlled concentrations that complement each other, ensuring complete coverage without excessive material accumulation in any single location
Solution Approach 2:
The concentration parameters of different deposition materials are carefully controlled and varied. By adjusting the concentration of first deposition material in the first area, second deposition material in the second area, and third deposition material in the third area, the system achieves complete layer coverage while preventing material piling up through optimized material deposition parameters
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
This approach reduces manufacturing time and costs while improving the quality of the display device by optimizing layer deposition, enhancing the refractive index and thickness uniformity across layers.
Implementation Method 1
a deposition source arranged in the chamber and including a first deposition part that ejects a first deposition material towards a display substrate and a second deposition part that ejects a second deposition material towards the display substrate
Data Source
AI summary
An apparatus for manufacturing a display device which deposits on a display substrate arranged in a virtual plane a first deposition material and a second deposition material. The apparatus may include a deposition source with multiple deposition parts that include differing deposition materials onto different areas or portions of the virtual plane. The deposition source moves with respect to the display substrate so that the deposition materials may be deposited onto the display substrate in case that at least one of the different areas of the virtual plane coincide with a location of the display substate.