Display Module Heater Control for Thin Protective Film Bumps

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Solution Overview

Problem

Existing display module manufacturing processes face challenges in improving the bending characteristics of display modules, particularly in reducing the thickness of bumps on protective films to prevent interference and enhance product reliability.

Innovation Solution

A display module manufacturing apparatus and method that includes a heater with side surfaces and a bump controller, along with a gas controller, to heat and modify the protective film, reducing the thickness of bumps and minimizing their contact, thereby enhancing bending characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the protective film is heated to form bumps for bending, then the bending characteristics are improved, but the bump thickness increases causing interference

Engineering Contradiction:
Improvebending characteristicsVSAvoidbump thickness
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by controlling the heating temperature and duration to precisely control the thickness of the bumps formed on the protective film. By adjusting these parameters, the bump thickness is optimized to achieve the desired bending characteristics while preventing excessive thickness that would cause interference.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent implements local quality by applying heat selectively to specific areas of the protective film where bumps are needed. The heating is localized rather than uniform, creating bumps only in the necessary regions to achieve proper bending characteristics while leaving other areas unaffected.

Inventive Principle:
Principle #3Local quality

2Use of energy by moving object

If the heater contacts the protective film directly, then heating efficiency is improved, but the bump thickness becomes excessive

Engineering Contradiction:
Improveheating efficiencyVSAvoidbump thickness
Core Design Contradiction:
Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The patent introduces an intermediary approach by positioning the heater at a controlled distance from the protective film rather than direct contact. This intermediate positioning allows heat to be transferred efficiently enough to form bumps while preventing excessive heat input that would result in overly thick bumps.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies preliminary action by pre-positioning the heater at the optimal distance and controlling the heating parameters before the actual bump formation process. This preliminary setup ensures that when heating occurs, the bump thickness is precisely controlled from the start, preventing excessive thickness.

Inventive Principle:
Principle #10Preliminary action

3Manufacturing precision

If the bump thickness is reduced, then interference is prevented, but the bending characteristics deteriorate

Engineering Contradiction:
Improvebump thicknessVSAvoidbending characteristics
Core Design Contradiction:
Manufacturing precisionVSReliability

Solution Approach 1:

The patent uses parameter changes to optimize the bump thickness to a precise value that balances two requirements: thin enough to prevent interference but thick enough to provide proper bending characteristics. By carefully adjusting heating parameters, the optimal thickness is achieved.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent implements feedback control by monitoring the bump formation process and adjusting heating parameters in real-time. This feedback mechanism ensures that the bump thickness reaches the optimal value without exceeding it, maintaining both thin enough to prevent interference and thick enough for proper bending.

Inventive Principle:
Principle #23Feedback

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

The apparatus and method effectively reduce bump thickness, preventing interference and improving the bending characteristics and reliability of the display module.

Implementation Method 1

heating a portion of the protective film using the heater and the bump controller

Methodology Applied
Scientific EffectHeating: Heating

Data Source

PatentUS12384140B2Display module manufacturing apparatus and display module manufacturing
Publication Date: 2025.08.12 SAMSUNG DISPLAY CO LTD
  • US12384140B2 patent drawing
  • US12384140B2 patent drawing
  • US12384140B2 patent drawing

AI summary

A display module manufacturing apparatus includes a stage on which a display module is disposed, a heater disposed on the stage, and configured to heat a first area of the display module, and wherein the heater includes a plurality of side surfaces and a contact surface, and a first bump controller detachably coupled to one side surface among the plurality of side surfaces and including a first bottom surface facing an upper surface of the stage. The contact surface is closer to the upper surface of the stage than the first bottom surface.