Mother Substrate Rib Partitions for Accurate OLED Inspection

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Solution Overview

Problem

There is a need for an effective and accurate inspection method during the manufacturing of OLED display devices to ensure that elements are formed as designed.

Innovation Solution

A mother substrate for a display device is designed with specific structural features, including a rib layer and partitions with overhang shapes, which facilitate precise etching processes and allow for high-accuracy inspections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional inspection methods are used for OLED display devices, then the manufacturing process is simple, but the inspection accuracy and effectiveness are insufficient

Engineering Contradiction:
Improveinspection accuracyVSAvoidsubstrate structure complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by forming inspection patterns and reference marks on the substrate before the actual OLED elements are manufactured. This allows inspection infrastructure to be prepared in advance, enabling accurate measurements without adding complexity to the element formation process itself. The inspection patterns are created during initial substrate processing steps.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent uses copying by creating test patterns that replicate the structure and materials of actual OLED elements on the same substrate. These copied structures serve as reference samples for inspection, allowing accurate measurement of element formation without needing to inspect every actual element individually. The test patterns copy the critical geometric and material properties of production elements.

Inventive Principle:
Principle #26Copying

2Reliability

If high-accuracy inspection is implemented, then element formation quality is ensured, but the manufacturing process becomes more complex and time-consuming

Engineering Contradiction:
Improveelement formation qualityVSAvoidmanufacturing efficiency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent merges inspection functionality with the manufacturing substrate by integrating inspection patterns, reference marks, and test elements directly into the substrate structure during production. This combination eliminates separate inspection substrate preparation steps and allows simultaneous use of the substrate for both element formation and inspection, maintaining productivity while ensuring quality.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The substrate is designed with multi-functionality, serving both as the base for OLED element formation and as the carrier for inspection patterns and reference marks. This universal substrate structure performs multiple functions - production and inspection - without requiring separate dedicated inspection substrates, thereby maintaining manufacturing efficiency while enabling comprehensive quality verification.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Measurement precision

If inspection patterns are added to the substrate, then inspection capability is improved, but the substrate area available for display elements is reduced

Engineering Contradiction:
Improveinspection capabilityVSAvoiddisplay element area
Core Design Contradiction:
Measurement precisionVSArea of stationary object

Solution Approach 1:

The patent applies local quality by placing inspection patterns, reference marks, and test elements in specific localized areas of the substrate - typically in peripheral regions or unused spaces - rather than distributing them uniformly across the entire substrate. This allows the majority of the substrate area to remain dedicated to display element formation while providing sufficient localized inspection infrastructure where needed.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS20250275377A1Mother substrate for display device and manufacturing method of display device
Publication Date: 2025.08.28 MAGNOLIA WHITE CORP
  • US20250275377A1 patent drawing
  • US20250275377A1 patent drawing
  • US20250275377A1 patent drawing

AI summary

According to one embodiment, a mother substrate for a display device includes panel portions each of which includes a display area and a surrounding area, a margin area around the panel portions, a lower electrode in the display area, a rib layer which has a pixel aperture, a first partition which is in the display area and surrounds the pixel aperture, and a second partition in at least one of the surrounding area and the margin area. The first partition includes a lower portion and an upper portion which has an end portion protruding from a side surface of the lower portion. The second partition includes a first portion which includes the lower portion and which does not include the upper portion.