Laser Cell Mask Separation for Defect Repair in OLED Mask Frames
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Solution Overview
Problem
The existing manufacturing processes for OLED displays face challenges in efficiently removing defective cell masks during the production of light emitting elements, which can lead to manufacturing inefficiencies and suboptimal display performance.
Innovation Solution
A mask repairing apparatus and method utilizing a laser to separate defective cell masks from an opening sheet by targeting the welding portions between the cell masks and the sheet, allowing for precise removal and replacement with normal cell masks, facilitated by a fixing part and suction part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to remove defective cell masks, then manufacturing process simplicity is maintained, but manufacturing efficiency and productivity deteriorate due to time-consuming manual removal processes
Solution Approach 1:
The patent replaces manual mechanical removal methods with a laser-based system. The laser beam precisely targets and removes defective cell masks by melting or vaporizing the material at the welding portion, significantly reducing removal time and improving manufacturing efficiency while automating the process.
Solution Approach 2:
The patent utilizes laser parameters (energy density, pulse duration, wavelength) to selectively remove defective cell masks. By controlling laser power and exposure time, the system achieves precise removal without damaging surrounding areas, enabling efficient automated defect correction.
2Manufacturing precision
If manual removal methods are used, then equipment complexity is kept low, but manufacturing precision and reliability worsen due to difficulty in achieving clean separation
Solution Approach 1:
The laser-based system provides precise control over the removal process, allowing for clean separation of defective cell masks from the opening sheet. The laser can be precisely positioned and controlled to remove only the defective portions without damaging surrounding areas, achieving high manufacturing precision.
Solution Approach 2:
The patent focuses on removing only the defective portions (welding portions) of the cell masks rather than entire masks. This segmented approach allows for selective repair, maintaining precision while minimizing material removal and reducing the need for complex handling apparatus.
3Reliability
If defective cell masks are not efficiently removed, then manufacturing process simplicity is maintained, but product quality and reliability deteriorate due to suboptimal display performance
Solution Approach 1:
The automated laser removal system efficiently eliminates defective cell masks, ensuring that only properly formed masks remain on the opening sheet. This improves display quality and reliability by preventing defective masks from affecting final product performance, while the automated nature maintains high manufacturing efficiency.
Solution Approach 2:
The laser system provides self-contained removal capability, where the defective portions are removed in-situ on the opening sheet without requiring complex external handling or multiple processing steps. This self-service approach ensures consistent quality improvement while maintaining 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
Enables efficient and precise removal of defective cell masks, improving manufacturing efficiency and ensuring consistent light emitting element production, thereby enhancing the quality and reliability of OLED displays.
Implementation Method 1
a laser which emits a laser beam toward a welding portion between an opening sheet disposed on a mask frame and a cell mask disposed on the opening sheet
Implementation Method 2
removing the welding portion by emitting the laser beam to the welding portion
Implementation Method 3
a suction part adjacent to the laser
Data Source
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AI summary
A mask repairing apparatus includes a laser which emits a laser beam toward a welding portion between an opening sheet disposed on a mask frame and a cell mask disposed on the opening sheet, a fixing part disposed below the opening sheet to fix the opening sheet, and a suction part adjacent to the laser. The cell mask is separated from the opening sheet by the laser beam.