Ink Leveling Plate for Uniform Light-Emitting Element Alignment
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Solution Overview
Problem
Existing display device manufacturing processes face challenges in uniformly aligning light-emitting elements, leading to non-uniform light emission due to uneven distribution and aggregation of light-emitting elements at the periphery of subpixels.
Innovation Solution
An ink leveling device with a stage, base frames, and moving members is used to press a target substrate, leveling light-emitting element ink and aligning elements by generating an electric field and irradiating ultraviolet light, ensuring uniform distribution and alignment of light-emitting elements across the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light-emitting element ink is sprayed onto the substrate without leveling, then the manufacturing process is simple and fast, but the light-emitting elements are unevenly distributed with aggregation at the periphery
Solution Approach 1:
The ink leveling device is divided into multiple independent components: a stage for holding the substrate, base frames providing structural support, moving members for positioning, and pressurizing members for applying pressure. This segmentation allows each component to perform its specific function independently, achieving uniform ink distribution while maintaining manufacturing simplicity.
Solution Approach 2:
A leveling liquid is introduced as an intermediary substance between the inkjet-printed ink and the substrate. The leveling liquid fills gaps and redistributes the ink uniformly across the substrate surface when pressurized, effectively solving the aggregation problem without requiring complex mechanical leveling mechanisms.
2Manufacturing precision
If a plate is used to press the target substrate for leveling, then uniform alignment of light-emitting elements is achieved, but the device structure becomes more complex
Solution Approach 1:
The pressurizing members serve multiple functions: they apply uniform pressure to level the ink, positions the light-emitting elements precisely, and can be adjusted for different substrate sizes and ink volumes. This multi-functionality reduces the need for separate leveling and positioning mechanisms, simplifying the overall device structure while maintaining high alignment precision.
Solution Approach 2:
The moving members enable dynamic adjustment of the pressurizing members' position and pressure application points. This dynamic capability allows the system to adapt to variations in substrate geometry and ink distribution patterns, achieving uniform alignment across different display device configurations without requiring multiple fixed pressing mechanisms.
3Manufacturing precision
If the size of the plate is larger than the target substrate, then complete coverage and uniform pressing is achieved, but material usage and device footprint increase
Solution Approach 1:
Instead of using a single large plate, the invention employs multiple pressurizing members with sizes matched to local regions of the substrate. Each pressurizing member applies pressure uniformly to its specific area, ensuring complete coverage and uniform pressing force distribution while minimizing the total material used and reducing the device footprint compared to a single oversized plate.
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
The solution improves light emission uniformity by preventing aggregation at the periphery and ensuring even alignment of light-emitting elements within subpixels, enhancing the overall luminance and alignment of display devices.
Implementation Method 1
pressing the target substrate by moving a plate
Implementation Method 2
aligning the light-emitting elements by forming an electric field on the target substrate
Implementation Method 3
irradiating ultraviolet light on the target substrate
Data Source
AI summary
An ink leveling device includes a stage on which a target substrate is disposed, base frames disposed at sides of the stage, moving members coupled to the base frames and movable upward and downward, and at least one plate coupled to the moving members and disposed to press the target substrate. Light-emitting element ink is disposed on the target substrate.