Display Manufacturing Source Unit Switching for Continuous Operation
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Solution Overview
Problem
The manufacturing efficiency of display apparatuses decreases when the operation of the manufacturing apparatus is stopped to replace components, leading to downtime and reduced productivity.
Innovation Solution
An apparatus and method that allow continuous operation during component replacement by using a chamber with multiple source units, a nozzle unit, and a regulating unit to control deposition material flow, along with temperature sensors to manage source unit operation and minimize downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the apparatus stops operation to replace components, then component maintenance can be performed, but manufacturing efficiency decreases
Solution Approach 1:
The patent implements continuous manufacturing operation by preparing multiple source units in advance. When one source unit needs maintenance or component replacement, another pre-prepared source unit immediately takes over, ensuring the manufacturing process never stops. This resolves the contradiction by maintaining continuous productivity while enabling seamless component maintenance.
Solution Approach 2:
The patent prepares backup source units in advance with all necessary components and deposition materials ready. This preliminary preparation allows for immediate substitution when a source unit requires maintenance, eliminating downtime and maintaining manufacturing efficiency while enabling easy component replacement.
2Productivity
If multiple source units are used with switching mechanisms, then continuous operation is enabled, but device complexity increases
Solution Approach 1:
The patent divides the deposition system into multiple independent source units, each capable of operating autonomously. This segmentation allows one source unit to be maintained or replaced while others continue operating. The regulating unit selectively connects active source units to the chamber, enabling continuous operation with manageable complexity through modular design.
Solution Approach 2:
The regulating unit serves multiple functions: it selectively connects different source units to the chamber, controls deposition material supply from each source unit, and manages the switching between source units. This multi-functionality reduces the need for separate control mechanisms for each source unit, thereby limiting the increase in device complexity while enabling continuous operation.
3Ease of repair
If source units are selectively connected and disconnected, then component recycling is enabled, but manufacturing process control becomes more complex
Solution Approach 1:
The regulating unit maintains continuous deposition material supply by selectively connecting source units based on their readiness status. When a source unit is being recycled or maintained, the regulating unit switches to another ready source unit, ensuring continuous operation. This selective connection mechanism enables component recycling without interrupting the manufacturing process or requiring complex control interventions.
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 continuous manufacturing without stopping the process for component replacement, reducing manufacturing time and increasing efficiency by managing source unit operation based on temperature and material availability.
Implementation Method 1
a plurality of source units outside the chamber, wherein the plurality of source units accommodate a deposition material and transform the deposition material into gas
Implementation Method 2
a nozzle unit in the chamber and connected to the plurality of source units, wherein the nozzle unit injects, into the chamber, the deposition material supplied from one of the plurality of source units
Implementation Method 3
a sensor unit in each of the plurality of source units and configured to measure an inner temperature of each of the plurality of source units
Implementation Method 4
The regulating unit may disconnect, from the nozzle unit, a source unit from among the plurality of source units, of which the inner temperature is greater than a pre-set temperature, and may connect, to the nozzle unit, a source unit from among the plurality of source units, of which the inner temperature is equal to or less than the pre-set temperature
Data Source
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AI summary
Described is an apparatus for manufacturing a display apparatus includes: a chamber; a plurality of source units outside the chamber, wherein the plurality of source units which accommodate a deposition material and transform the deposition material into gas; a nozzle unit in the chamber, wherein the nozzle unit is connected to the plurality of source units and injects, into the chamber, the deposition material supplied from one of the plurality of source units; and a regulating unit between each of the plurality of source units and the nozzle unit, wherein the regulating unit interrupts the deposition material supplied from each of the plurality of source units to the nozzle unit and selectively connects the plurality of source units with the nozzle unit.