Display Manufacturing Spraying Device for Nozzle Discharge Uniformity
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Solution Overview
Problem
Existing display manufacturing technologies face issues with luminance differentials and Line Mura due to variations in nozzle discharge amounts during the formation of optical patterns, color filters, or light emitting layers in display panels.
Innovation Solution
A method and device that uniformly distribute nozzle sets across application areas by activating specific nozzle groups to ensure consistent material distribution, using a controller to manage nozzle activation based on discharge amount ranges divided into predefined areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all nozzles are activated to spray material across the entire substrate, then productivity is improved, but luminance differential and Line Mura occur due to variations in nozzle discharge amounts
Solution Approach 1:
The substrate is divided into multiple application areas, and the nozzles are segmented into different nozzle groups based on their discharge amount characteristics. Each nozzle group is responsible for specific application areas, allowing selective activation of nozzles to maintain uniform material distribution while covering the entire substrate efficiently.
Solution Approach 2:
Different nozzle groups with different discharge amount characteristics are assigned to different application areas. Nozzles with higher discharge amounts are strategically distributed to areas requiring less material, while nozzles with lower discharge amounts serve areas requiring more material, achieving local optimization of material distribution.
2Manufacturing precision
If nozzles are selectively activated to maintain uniform discharge distribution, then luminance uniformity is improved, but device complexity increases due to nozzle group management
Solution Approach 1:
The nozzles are pre-classified into different nozzle groups based on their discharge amount characteristics before the spraying process begins. This preliminary classification and the predetermined distribution pattern of nozzle groups across application areas simplify the control logic during actual operation, as the controller only needs to activate appropriate nozzle groups based on the application area being processed.
Solution Approach 2:
The system changes the operational parameters by selectively activating different nozzle groups based on the application area. The controller adjusts which nozzles are active according to the specific area being sprayed, optimizing discharge uniformity without requiring complex real-time adjustments during the spraying process.
3Area of stationary object
If nozzle discharge amounts are varied to cover different application areas, then area coverage is improved, but manufacturing precision deteriorates due to inconsistent material distribution
Solution Approach 1:
Different nozzle groups with different discharge amount characteristics are assigned to different application areas. Nozzles with higher discharge amounts are strategically distributed to areas requiring less material, while nozzles with lower discharge amounts serve areas requiring more material, achieving local optimization of material distribution.
Solution Approach 2:
The system incorporates measurement of actual discharge amounts for each nozzle and uses this information to determine the appropriate grouping and distribution of nozzles. This feedback mechanism allows the system to compensate for variations in nozzle performance and achieve uniform material distribution across the entire substrate area.
Data Source
AI summary
A method of manufacturing a display device includes preparing a spraying device including a plurality of nozzles, dividing a discharge amount value range between a first reference discharge amount value and a second reference discharge amount value into k areas (k is a natural number), generating nozzle sets by combining n nozzles (n is a natural number) among m nozzles (m is a natural number, m≥n) for each of a plurality of nozzle groups, where the nozzle sets have a same discharge amount value as one another or different discharge amount values from one another, and each of the plurality of nozzle groups is defined by the m nozzles among the plurality of nozzles, and deriving an active nozzle group in which the nozzle sets are distributed in a preset manner in the k areas from the plurality of nozzle groups.