Nozzle Vibration for Organic Material Deposition in Display Manufacturing
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Solution Overview
Problem
The manufacturing of display apparatuses faces challenges in efficiently supplying and processing organic materials for display panels, particularly in maintaining consistent particle size and preventing material deposition during the evaporation process.
Innovation Solution
An apparatus comprising an organic material supply unit, a bagging pump unit, an organic material adjusting unit, and a nozzle unit with a stepped structure and a vibrator, which controls the flow of organic material, adjusts its temperature, and optimizes power consumption to ensure uniform evaporation and prevent deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If organic material is supplied continuously to the nozzle unit, then productivity is improved, but material deposition on the nozzle occurs causing manufacturing precision to deteriorate
Solution Approach 1:
The nozzle unit is vibrated periodically at a specific frequency (e.g., 20-50 kHz) to prevent organic material deposition while maintaining continuous supply. The periodic vibration creates oscillatory flow that prevents material accumulation on the nozzle surface, thereby maintaining particle size consistency without reducing productivity.
Solution Approach 2:
A vibration generator is attached to the nozzle unit to apply mechanical vibrations that prevent organic material from adhering to the nozzle surface. This vibration mechanism ensures consistent particle formation by preventing deposition, allowing continuous high-rate supply without compromising manufacturing precision.
2Productivity
If the nozzle unit operates at high power to maintain temperature, then evaporation efficiency is improved, but power consumption increases
Solution Approach 1:
A temperature sensor is integrated into the nozzle unit to monitor the temperature in real-time. The control unit receives this feedback and adjusts the power supplied to the heater accordingly, maintaining the optimal temperature for evaporation while minimizing power consumption. This closed-loop control ensures efficient evaporation without excessive energy use.
Solution Approach 2:
The system dynamically adjusts operational parameters including temperature, vibration frequency, and power consumption based on real-time conditions. By optimizing these parameters, the system maintains high evaporation efficiency while minimizing energy consumption, adapting to varying material properties and environmental conditions.
3Productivity
If the nozzle unit is heated to high temperature for evaporation, then evaporation rate is improved, but component lifespan deteriorates
Solution Approach 1:
The temperature sensor continuously monitors the nozzle temperature and provides feedback to the control unit. This feedback mechanism prevents overheating by maintaining the temperature within an optimal range, ensuring high evaporation rates while preventing thermal degradation and extending the nozzle's operational lifespan.
Solution Approach 2:
The periodic vibration of the nozzle unit prevents material deposition that would otherwise require high temperatures for removal. This periodic action reduces thermal stress on the nozzle, allowing efficient evaporation at lower temperatures and thereby extending component lifespan.
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 apparatus ensures consistent and uniform supply of organic material, reducing particle size and preventing deposition, thereby enhancing the manufacturing efficiency and performance of display apparatuses.
Implementation Method 1
a vibrator that is connected to the nozzle, the vibrator vibrating according to a voltage applied thereto from an outside thereof
Implementation Method 2
a barrel in which organic material emitted from the nozzle unit is evaporated
Implementation Method 3
a plate heater on the top plate
Data Source
AI summary
An apparatus for manufacturing a display apparatus, the apparatus including an organic material supply unit; a bagging pump unit that is connected to the organic material supply unit such that the organic material supply unit supplies an organic material to the bagging pump unit; an organic material adjusting unit that is connected to the bagging pump unit such that the bagging pump unit selectively supplies the organic material to the organic material adjusting unit; and a nozzle unit that is connected to the organic material adjusting unit such that the organic material adjusting unit adjusts an amount of the organic material provided to the nozzle unit, the nozzle unit changing the organic material into particles and spraying the particles.