Mask-Based Sealant Application for Flat Panel Display Manufacturing
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Solution Overview
Problem
Existing methods for forming seal patterns in flat panel display devices are inefficient and time-consuming, particularly when dealing with changes in display panel size, which hampers productivity and adaptability to larger display panels.
Innovation Solution
An apparatus and method utilizing a mask with openings and bridges of straight or mesh shape on a mother substrate, combined with a seal head and controller, to apply a sealant uniformly around the periphery of unit display panels, allowing for efficient seal pattern formation regardless of panel size changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional seal pattern formation methods are used, then the process can be completed, but the time required increases significantly and productivity decreases
Solution Approach 1:
The mask is divided into multiple opening regions corresponding to different unit display panels on the mother substrate. Each opening allows sealant to be applied simultaneously to multiple panels through a single mask structure, enabling parallel processing and significantly reducing the time required to form seal patterns across multiple panels.
Solution Approach 2:
The mask is prepared in advance with pre-formed openings and bridges positioned according to the layout of unit display panels on the mother substrate. This preliminary configuration of the mask structure eliminates the need for time-consuming on-site positioning and adjustment, allowing for rapid sealant application directly to the predetermined locations.
2Adaptability or versatility
If display panel size changes, then adaptability is improved, but the seal pattern formation process becomes more complex and time-consuming
Solution Approach 1:
The mask structure with its opening and bridge configuration is designed to be universally applicable to different display panel sizes and layouts. The same mask type can accommodate various unit display panel arrangements on the mother substrate by simply changing the mask positioning, eliminating the need to redesign the mask structure or change the sealant application process when panel dimensions vary.
3Manufacturing precision
If sealant is applied manually without mask guidance, then flexibility is maintained, but uniformity of seal pattern and tack time consistency deteriorate
Solution Approach 1:
The mask acts as an intermediary tool between the sealant application source and the unit display panels. The mask's openings and bridges provide precise geometric guidance that ensures uniform sealant distribution and consistent tack times across all seal patterns, while the overall process remains simple through automated or semi-automated application.
Data Source
AI summary
Disclosed herein is an apparatus and method for forming a seal pattern of a flat panel display device. An apparatus for forming a seal pattern of a flat panel display panel includes a mother substrate having a plurality of unit display panels formed thereon; a stage to support the mother substrate; a mask on the mother substrate, the mask having openings, each opening being formed on a region corresponding to an outer periphery of each unit display panel; and a pattern forming unit including a seal head to apply a sealant to the mask to form the seal pattern around the outer periphery of each unit display panel of the mother substrate.