Display Panel Bending Inspection via Acoustic Emission
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Solution Overview
Problem
Current inspection methods for bending defects in display panels are inefficient and lack precision, particularly in detecting cracks and curvature-related issues during the bending process, which can lead to manufacturing inefficiencies and defective products.
Innovation Solution
An inspection apparatus comprising support members, a bending-pressing member, sound wave sensors, and cameras that support and bend the display panel to detect cracks by analyzing sound waves and image differences before and after the bending process, allowing for precise detection of defects and optimal curvature determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated inspection using sound wave sensors and cameras is implemented, then measurement precision and reliability are improved, but device complexity increases
Solution Approach 1:
The inspection apparatus is divided into functionally independent modules: support members for positioning, bending-pressing member for applying controlled stress, sound wave sensors for acoustic emission detection, and cameras for visual documentation. Each module performs a specific function, allowing the system to achieve high measurement precision through specialized components while managing overall complexity through modular design.
Solution Approach 2:
Sound wave sensors act as intermediaries between the bending-pressing member and the crack detection system. The sensors detect acoustic emissions generated when cracks form during the bending process, providing indirect but precise measurement of defect locations without requiring direct contact or complex imaging during the actual detection moment.
2Reliability
If multiple sensors and cameras are used for comprehensive inspection, then reliability of defect detection is improved, but loss of time in the inspection process increases
Solution Approach 1:
The inspection process operates continuously through coordinated action of all components. The support members continuously hold the display panel, the bending-pressing member applies continuous or cyclic bending stress, sound wave sensors continuously monitor for acoustic emissions, and cameras capture images at critical moments. This continuous operation eliminates idle time between inspection steps while maintaining high reliability through multiple sensing modalities.
Solution Approach 2:
The support members and bending-pressing member are pre-positioned before the inspection begins. The system prepares the display panel in the correct orientation and applies preliminary bending to reach the inspection curvature before activation of sensors and cameras, ensuring that the inspection phase can proceed immediately without setup delays.
3Manufacturing precision
If the bending-pressing member applies precise micrometer-level pressure, then manufacturing precision of the inspection process is improved, but the device complexity increases
Solution Approach 1:
The pressing mechanism replaces complex mechanical positioning systems with a simpler actuation system controlled by the inspection controller. The controller manages the bending-pressing member to achieve the required micrometer-level precision through electronic control rather than purely mechanical means, reducing mechanical complexity while maintaining manufacturing precision.
Solution Approach 2:
The inspection curvature is defined as a specific parameter that the bending-pressing member must achieve. By establishing the target curvature as a controllable parameter, the system can adjust the pressing force and positioning to reach the desired inspection conditions without requiring equally precise mechanical tolerances throughout the entire mechanism, thereby reducing overall device complexity.
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 automates the inspection of bending defects, enabling accurate detection of cracks and curvature conditions, thereby improving manufacturing efficiency and ensuring high-quality display panels by identifying defects through sound wave analysis and image comparison.
Implementation Method 1
a sound wave sensor that senses a sound wave generated from the display panel during a bending inspection process
Data Source
AI summary
An inspection apparatus includes: a plurality of support members that support a display panel at a predetermined height; a bending-pressing member that presses a pressing surface of the display panel; a sound wave sensor that senses a sound wave generated from the display panel during a bending inspection process, wherein during the bending inspection process, the bending-pressing member presses the pressing surface of the display panel; and an inspection controller that detects a crack in the display panel using the sound wave sensed by the sound wave sensor.