Inkjet Color Filter Fabrication with Optical Feedback Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for fabricating color filters, such as dyeing, pigment dispersion, and printing, are inefficient and costly due to the need for repeated processes to form red, green, and blue pixels, and inkjet processes often result in unsatisfactory pixels due to abnormal ink ejection.
Innovation Solution
An apparatus and method using an inkjet head with a light source and photodetector to determine pixel quality, allowing for real-time adjustment of ink droplet size and number to ensure satisfactory pixel formation, incorporating an analyzer to control the inkjet head based on detected light transmittance and intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inkjet process is used to fabricate color filter, then fabrication cost and process complexity are reduced, but pixel quality becomes unsatisfactory due to abnormal ink ejection
Solution Approach 1:
The patent implements a feedback control system where a light source illuminates the printed pixel, a photodetector measures the transmitted light to determine pixel quality, and the system automatically performs re-printing when abnormal ejection is detected. This closed-loop feedback mechanism ensures high pixel quality while maintaining the simplicity of the inkjet fabrication process.
Solution Approach 2:
The patent performs preliminary quality detection immediately after ink ejection by measuring light transmittance through the printed pixel. By detecting abnormalities early in the process and performing re-printing before the substrate moves to the next position, the system prevents defective pixels from being produced, ensuring high manufacturing precision.
2Manufacturing precision
If multiple printing steps are repeated to form each pixel, then pixel quality can be improved, but fabrication time and cost increase
Solution Approach 1:
The system uses real-time feedback from the photodetector to determine whether re-printing is necessary. By only performing additional printing steps when abnormal ejection is detected rather than uniformly printing multiple times for all pixels, the system maintains high pixel quality while minimizing unnecessary fabrication time and cost.
Solution Approach 2:
The patent applies partial action by performing quality detection and re-printing only on pixels where abnormal ejection is detected, rather than uniformly processing all pixels through multiple printing steps. This selective approach improves pixel quality where needed while maintaining high overall fabrication efficiency.
3Device complexity
If ink droplet ejection is not monitored, then fabrication process is simpler, but unsatisfactory pixels are produced due to abnormal ejection
Solution Approach 1:
The patent implements a monitoring system using a light source and photodetector that measures light transmittance through each printed pixel to detect abnormal ink ejection. The system provides feedback control by automatically triggering re-printing when defects are detected, ensuring high pixel formation reliability while adding only minimal process complexity.
Solution Approach 2:
The system performs self-diagnosis and self-correction by automatically detecting abnormal ink ejection through optical measurement and triggering re-printing without external intervention. This self-service mechanism ensures reliable pixel formation while keeping the monitoring system relatively simple.
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 enhances the quality of printed pixels by allowing for immediate correction of unsatisfactory pixels, reducing waste and improving the efficiency and cost-effectiveness of the color filter fabrication process.
Implementation Method 1
a light source for emitting light and a photodetector for detecting the light... determine the quality of the printed pixel based on a transmittance of the printed pixel
Data Source
AI summary
An apparatus and method for fabricating a color filter by printing pixels on a substrate using an ink jet head, optically analyzing pixel quality and controlling printing in accordance with the pixel quality. Optically analyzing may include analyzing a number of ink droplets or a transmittance of a printed pixel.