Dynamic Laser Processing for Uniform Optical Holes in Display Devices
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Solution Overview
Problem
Current display device manufacturing processes are inefficient in forming optical holes for optical elements, as they lack a rapid and precise method for laser processing, which is essential for integrating various functional components like cameras and sensors.
Innovation Solution
An apparatus and method that involve a scanner and stage movement during laser processing to form uniform spot intervals of a laser beam, allowing for rapid and precise formation of optical holes by synchronizing pulse signals with the movement of the scanner and stage, enabling efficient integration of optical elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stationary laser processing method is used to form optical holes, then the manufacturing process is simple to implement, but the processing speed is slow and manufacturing efficiency is low
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a stationary laser processing system to a dynamic system where both the scanner and stage move simultaneously during laser processing. The scanner moves to deflect the laser beam across the substrate while the stage moves to position different areas of the substrate under processing, creating a coordinated dynamic system that dramatically increases processing speed while maintaining precision through synchronized control.
2Manufacturing precision
If the laser beam is irradiated while only the scanner moves, then the device complexity is reduced, but the spot intervals between laser beams become non-uniform
Solution Approach 1:
The patent implements feedback control by continuously monitoring the positions of both the scanner and stage, and using this information to dynamically adjust laser irradiation timing and positioning. The control system receives position feedback from encoders on both the scanner and stage, calculates the optimal laser firing moments to achieve uniform spot intervals, and adjusts the irradiation pattern in real-time to compensate for any position variations, ensuring precise uniform spacing.
3Productivity
If a rapid laser processing method moving both scanner and stage is implemented, then the manufacturing efficiency is improved, but the control system complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing the optimal movement trajectories and laser irradiation timing sequences before actual processing begins. The control system pre-determines the coordinated motion paths of the scanner and stage, and pre-schedules when laser pulses should be emitted to achieve uniform spot patterns, allowing the system to execute complex high-speed processing with simplified real-time control.
4Manufacturing precision
If pulse signals are not synchronized with scanner and stage movement, then the control system is simpler, but the laser processing precision and uniformity deteriorate
Solution Approach 1:
The patent implements feedback control by continuously monitoring the positions of both the scanner and stage, and using this information to dynamically adjust laser irradiation timing and positioning. The control system receives position feedback from encoders on both the scanner and stage, calculates the optimal laser firing moments to achieve uniform spot intervals, and adjusts the irradiation pattern in real-time to compensate for any position variations, ensuring precise uniform spacing.
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 enables a faster and more precise laser processing method, enhancing the manufacturing efficiency of display devices by allowing for the effective integration of optical elements and other functional components.
Implementation Method 1
a laser module disposed above the stage and configured to output a laser beam
Data Source
AI summary
An apparatus for manufacturing a display device and a method for manufacturing a display device are provided. The apparatus includes a stage; a laser module disposed above the stage and configured to output a laser beam; a scanner configured to receive the laser beam output from the laser module and irradiate the laser beam onto the stage; and a controller configured to control the laser module to irradiate the laser beam to a processing position while moving both the scanner and the stage in a first direction according to the processing position and a shape of a processing pattern.