Flat Panel Display Sealant Hardening via Laser and CCD Monitoring
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Solution Overview
Problem
Conventional encapsulating structures for organic light-emitting display devices face sealing flaws due to irregular laser energy distribution during the hardening of sealants, leading to incomplete sealing, especially at the start and end points of laser irradiation, which can result in water permeation and device deterioration.
Innovation Solution
A method involving real-time monitoring of sealant hardening using a CCD camera and controlled laser irradiation, with a second hardening process to supplement energy to regions with insufficient hardening, utilizing a sealant hardening mask with a light transmitting slit and adjusting laser power to 70-80% of the initial power for the second hardening, to ensure complete sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If laser irradiation is applied to harden the sealant, then the sealant hardening speed is improved, but the hardening uniformity deteriorates due to irregular energy distribution
Solution Approach 1:
The hardening process is divided into two distinct stages: first hardening with full laser power to achieve rapid hardening, and second hardening with reduced laser power (70-80% of initial power) to correct insufficiently hardened regions. This segmentation allows each stage to optimize for its specific purpose, resolving the contradiction between speed and uniformity.
Solution Approach 2:
The laser irradiation is applied in periodic pulses rather than continuously. The first pulse delivers high energy for rapid hardening, followed by a second pulse with reduced energy to supplement areas that didn't harden sufficiently. This periodic action pattern enables both fast processing and uniform results.
2Productivity
If high laser power is used for first hardening, then the hardening efficiency is improved, but the risk of insufficient hardening in certain regions increases
Solution Approach 1:
The first hardening process with high laser power performs the preliminary action of hardening most of the sealant quickly and efficiently. The system then uses monitoring to identify regions that didn't harden sufficiently, and applies a second hardening process specifically to those areas. This preliminary action approach maintains high productivity while ensuring reliability through targeted correction.
Solution Approach 2:
A monitoring system detects the hardening state of the sealant in real-time during the first hardening process. This feedback information is used to identify regions in a 'bad hardening state' that require additional laser irradiation. The feedback loop ensures that high initial power doesn't compromise reliability, as problematic areas are automatically detected and corrected.
3Reliability
If laser irradiation is applied to seal the encapsulating structure, then the sealing function is achieved, but sealing flaws occur at start and end points due to energy insufficiency
Solution Approach 1:
The second hardening process applies laser power locally to specific regions that were insufficiently hardened during the first process. By concentrating energy on boundary areas and regions in bad hardening state rather than uniformly irradiating the entire sealant, the system achieves high sealing quality at critical locations without compromising overall efficiency.
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 prevents sealing flaws by ensuring uniform hardening of the sealant, resulting in a more stable and solid sealed structure that effectively prevents water permeation and enhances the durability of the flat panel display device.
Implementation Method 1
irradiating light onto a sealant area to harden the sealant
Implementation Method 2
The light may include a laser light
Implementation Method 3
real-time monitoring of the sealant area through a charge-coupled device (CCD) camera
Implementation Method 4
installing a neutral density (ND) filter in the CCD camera
Data Source
AI summary
A method of sealing a flat panel display device by using laser and a charge-coupled device (CCD) camera. The sealing method includes applying a sealant around a light-emitting unit on a substrate and covering above the light-emitting unit with the encapsulating substrate; irradiating light onto a sealant area to harden the sealant for the first time (first hardening); monitoring a hardening state of the sealant; and further irradiating light onto a region of the sealant in a bad hardening state based on the monitoring result to harden the region of the sealant in the bad hardening state (second hardening). The sealing method may prevent a sealing flaw caused from insufficient laser irradiation dosage, and thus ensure a more stable sealed structure. This may improve quality of the flat-plan-display-device.