Laminated Light Emitting Display Panel Inner Pressure Reduction
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Solution Overview
Problem
Thin light emitting devices experience increased inner pressure during reliability tests under high temperature and high humidity, leading to failure due to non-contacting contact electrodes between substrates.
Innovation Solution
A method involving a vacuum chamber where substrates are held and aligned, with a high vacuum created and a heated gas (50-200°C) introduced to temporarily laminate and bond them, reducing initial inner pressure to 20-35 torr.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If substrates are laminated using inert gas at room temperature, then the initial inner pressure is about 30-40 torr, but the inner pressure increases to above 100 torr during high temperature and high humidity reliability tests causing contact electrode failure
Solution Approach 1:
The patent applies parameter changes by introducing heated inert gas (at elevated temperature) during the lamination process instead of room temperature gas. This temperature parameter change causes the gas to expand and reduces the initial inner pressure to 20-35 torr. The heated gas also creates a pressure gradient that facilitates better contact between substrates, and the lower initial pressure provides a margin that prevents contact electrode failure during subsequent high temperature and humidity reliability tests.
2Reliability
If the inner pressure is reduced to prevent contact electrode non-contact, then the reliability improves, but the manufacturing process complexity increases due to vacuum chamber requirements
Solution Approach 1:
The patent employs an inert atmosphere (inert gas) in the vacuum chamber during the lamination process. This inert environment prevents oxidation and contamination of the contact electrodes and other sensitive components while the vacuum system maintains the reduced pressure condition. The inert atmosphere is essential for achieving the 20-35 torr pressure range and maintaining it during the heating and bonding process, thereby ensuring contact electrode reliability without excessive complexity increase.
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 reduces inner pressure, preventing panel failure and enhancing reliability in high temperature and humidity environments without damaging the device.
Implementation Method 1
creating a high vacuum in the vacuum chamber
Implementation Method 2
supplying gas having a temperature of about 50 to about 200° C. into the vacuum chamber
Implementation Method 3
venting the vacuum chamber; and bonding the first substrate and the second substrate
Data Source
AI summary
A method for manufacturing light emitting devices is provided. The method may reduce the inner pressure of a laminated image emitting device panel, thereby preventing failure of the panel. The method includes holding a first substrate with a lower chuck located in a vacuum chamber; holding a second substrate with an upper chuck located opposite the first chuck in the vacuum chamber; creating a high vacuum in the vacuum chamber; correcting positions of the first substrate and the second substrate; supplying gas having a temperature of about 50 to about 200° C. into the vacuum chamber; temporarily laminating the first substrate and the second substrate; venting the vacuum chamber; and bonding the first substrate and the second substrate. The panel is laminated after being filled with a heated gas and thus, when it is exposed to room temperature, the mobility of the gas decreases while reducing its initial inner pressure, thereby preventing panel failure.