Inkjet Display Coating for Uniform Scatterer Distribution
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Solution Overview
Problem
Existing methods for manufacturing display devices face challenges in forming uniform light control patterns, particularly in ensuring consistent distribution of scatterers and quantum dots across pixel areas, leading to variations in weight ratios and optical properties.
Innovation Solution
A method using an inkjet apparatus with multiple head units applies a liquid composition including scatterers and quantum dots to display substrate areas through controlled scanning stages, shifting head units to distribute the composition evenly across pixel areas, ensuring uniformity and reducing weight ratio differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single head unit is used to apply liquid composition to multiple unit display areas, then the manufacturing process is simple, but the distribution of scatterers becomes non-uniform across the display areas
Solution Approach 1:
The inkjet apparatus is divided into multiple head units (first head unit with i unit areas, second head unit with i unit areas) that operate independently to apply liquid composition to different sets of unit display areas. This segmentation allows each head unit to cover a specific region, ensuring uniform scatterer distribution across the entire display substrate without requiring a single complex head unit.
2Manufacturing precision
If multiple scanning stages are performed without compensation, then the manufacturing process is efficient, but the first unit display area receives excessive liquid composition leading to non-uniform scatterer distribution
Solution Approach 1:
A compensation scanning stage is introduced that uses feedback from the scanning pattern to correct the over-application problem. The first head unit performs j normal scanning stages applying liquid composition to unit display areas, then performs a compensation scanning stage where it applies liquid composition to only (i-1) unit display areas (excluding the first unit display area). This feedback-based compensation ensures uniform total application across all scanning stages while maintaining manufacturing efficiency.
3Manufacturing precision
If the inkjet apparatus applies liquid composition quickly, then productivity is high, but the scatterers are intensively distributed to specific areas causing non-uniformity
Solution Approach 1:
The inkjet apparatus is configured with multiple head units and a compensation scanning stage that perform preliminary actions to prevent intensive scatterer distribution before it occurs. The compensation scanning stage proactively adjusts the application pattern to ensure uniform distribution across all unit display areas, preventing the need for time-consuming post-manufacturing corrections while maintaining high productivity.
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 method effectively prevents intensive distribution of scatterers to specific areas, achieving uniform light control patterns and reducing variations in optical properties, thereby enhancing display quality.
Implementation Method 1
A method using an inkjet apparatus with multiple head units applies a liquid composition including scatterers and quantum dots to display substrate areas through controlled scanning stages
Implementation Method 2
shifting head units to distribute the composition evenly across pixel areas, ensuring uniformity and reducing weight ratio differences
Data Source
AI summary
A method of manufacturing a display device, which is provided using an inkjet apparatus that provides a liquid composition including a scatterer, includes performing j scanning stages to provide a first composition to i unit display areas among n unit display areas (j is a natural number equal to or greater than 2), and performing a first compensation-scanning stage to provide the first composition to first to (i−1)-th unit display areas among the n unit display areas. The i unit areas of the first head unit provide the first composition to the first unit display area to an i-th unit display area among the n unit display areas in a first scanning stage among the j scanning stages. The first head unit is shifted in the second direction by one unit display area in every scanning stage of the j scanning stages.