Display Substrate Planarization Using Laser-Heated Protrusion Pins
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display devices face challenges in integrating additional functions and expanding display areas while maintaining a compact form factor, particularly in creating transmission areas that are seamlessly integrated with display panels.
Innovation Solution
A manufacturing apparatus and method that forms a display apparatus with a stack structure of a display panel, including a stage with a heat transfer unit and a laser unit to form an organic layer, allowing for the creation of a bending or curved non-display area to accommodate transmission components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a transmission area is provided to the display panel, then additional functions and components can be integrated, but the structural complexity and manufacturing difficulty increase due to bending or curved stack structures in the non-display area
Solution Approach 1:
The patent applies parameter changes by controlling the temperature distribution during organic layer formation. The heat transfer unit with protrusion pins creates localized temperature variations that allow the organic layer to be deposited on a curved or bending stack structure and then planarized through controlled heating and cooling cycles, transforming the physical state and properties of the materials involved.
Solution Approach 2:
The heat transfer unit acts as an intermediary between the laser heating source and the organic material layer. It transfers thermal energy selectively to specific regions, enabling precise control over the curing and planarization process of the organic layer without directly exposing the entire stack structure to high temperatures.
2Adaptability or versatility
If an organic layer is formed to planarize the stack structure, then additional functions can be integrated, but the manufacturing process complexity increases due to temperature control requirements
Solution Approach 1:
The heat transfer unit is segmented into multiple protrusion pins that can be independently positioned and controlled. This segmentation allows selective heating of different regions of the organic layer, enabling complex planarization patterns to be achieved through simple, localized thermal actions rather than requiring complex overall temperature control systems.
Solution Approach 2:
The patent replaces complex mechanical planarization systems with a thermal field-based approach. Instead of using mechanical pressure or physical contact methods to flatten the organic layer, the invention uses controlled thermal fields generated by the heat transfer unit to achieve planarization through thermal expansion, softening, and curing effects.
3Productivity
If the heat transfer unit is positioned close to the organic material layer for effective heating, then planarization efficiency improves, but the risk of overheating and damaging the display substrate increases
Solution Approach 1:
The heat transfer unit with protrusion pins implements local quality by concentrating thermal energy only where needed - specifically at the organic layer and immediate underlying structures. The protrusion pins create localized high-temperature zones for efficient planarization while the rest of the substrate remains at safe temperatures, achieving high productivity without substrate damage.
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
Enables the integration of additional components and functions within the display area by forming a planarized stack structure, enhancing the versatility and functionality of display devices.
Implementation Method 1
a laser unit configured to irradiate a laser beam to the heat transfer unit
Implementation Method 2
a heat transfer unit arranged on the jig and including a protrusion pin protruding toward the second surface
Implementation Method 3
an ultraviolet irradiator configured to irradiate an ultraviolet ray toward the organic material discharged
Implementation Method 4
forming an organic layer by hardening the organic material layer
Data Source
AI summary
An apparatus for manufacturing a display apparatus is provided. The apparatus includes a stage that has a first surface and a second surface. A display substrate is arranged on the first surface, and the second surface is opposite to the first surface. The apparatus also includes a jig facing the second surface, a heat transfer unit arranged on the jig and including a protrusion pin protruding toward the second surface, and a laser unit configured to irradiate a laser beam to the heat transfer unit.