Droplet Volume Measurement Using Multi-Directional Optical Scanning
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Solution Overview
Problem
Existing droplet measurement methods for display device manufacturing are prone to errors due to reliance on two-dimensional imaging and assumptions of smooth droplet surfaces, leading to inconsistencies in light-emitting layer formation.
Innovation Solution
A method and apparatus that use optical scanners to measure droplet thicknesses by scanning in a direction perpendicular to the scanners, calculating volume through mensuration by parts, ensuring accurate droplet volume measurement and adjustment for uniform light-emitting layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two-dimensional imaging methods are used to measure droplet volume, then the measurement process is simple, but the measurement precision deteriorates due to errors from assuming smooth droplet surfaces
Solution Approach 1:
The patent transitions from two-dimensional imaging to three-dimensional measurement by scanning the droplet surface with optical scanners at multiple positions. The scanning unit moves in a first direction while optical scanners measure thickness in a second direction perpendicular to the first, building a three-dimensional profile of the droplet surface that captures actual surface topology rather than assuming smoothness.
Solution Approach 2:
The droplet measurement is divided into multiple discrete scanning positions along the first direction. At each position, the optical scanner measures thickness at multiple points in the second direction. This segmentation of the measurement process into discrete sampling points allows reconstruction of the complete three-dimensional droplet profile through data aggregation.
2Productivity
If droplet volume measurement is not performed accurately, then the manufacturing process is faster, but the manufacturing precision deteriorates causing height differences in light-emitting layers
Solution Approach 1:
The droplet volume measurement is performed before the inkjet printing process using a scanning unit that maps the complete three-dimensional profile of each droplet. This preliminary measurement provides accurate volume data that is used to adjust subsequent droplet discharge parameters, ensuring uniform light-emitting layer formation while maintaining manufacturing efficiency through automated feedback control.
Solution Approach 2:
The measurement system provides feedback on actual droplet volume and shape characteristics to the inkjet printing process. Based on the three-dimensional scanning data, the system adjusts discharge parameters to compensate for variations in droplet formation, ensuring consistent light-emitting layer height and preventing defects such as stains or irregularities.
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 provides accurate droplet volume measurement, allowing for precise adjustment of discharge amounts and preventing height differences in light-emitting layers, thus enhancing display device quality.
Implementation Method 1
measuring the thicknesses of the portions of the droplet by receiving the light reflected from the droplet by each of the optical scanners
Data Source
AI summary
A droplet measurement method is described. The droplet measurement method may include discharging a droplet on a substrate, scanning the droplet by moving a scanning unit, and calculating a volume of the droplet by using the thicknesses of the portions of the droplet. The scanning unit may include optical scanners arranged in multiple directions, storing thicknesses of portions of the droplet scanned by the scanning unit.