OLED Cover Layer Mask Rotation for Simultaneous Cleaning
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Solution Overview
Problem
The existing manufacturing processes for organic light emitting diode (OLED) displays face challenges due to residual organic materials, such as resin, remaining on mask bridges, which disrupt the contact between the mask and the mother substrate and reduce the reliability of the display device.
Innovation Solution
An apparatus and method are introduced that allow for simultaneous application and cleaning processes using different masks, enabling continuous and sequential application processes while maintaining mask cleanliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cleaning process is performed between applying processes to remove resin from the mask, then the reliability of the display device is improved, but the applying processes cannot be performed continuously
Solution Approach 1:
The system divides the mask handling into separate functional units: an applying unit for resin application and a cleaning unit for mask cleaning. Multiple masks are segmented and distributed across these units, allowing one mask to be cleaned while another is used for applying, thus resolving the contradiction between cleaning reliability and process continuity.
Solution Approach 2:
The invention implements continuous operation by having the cleaning process and applying process occur simultaneously in different units. While Mask 1 is being used in the applying unit, Mask 2 is being cleaned in the cleaning unit, ensuring that the useful action of resin application continues without interruption.
2Productivity
If multiple masks are used for simultaneous applying and cleaning processes, then the productivity and continuity of the manufacturing process is improved, but the device complexity increases
Solution Approach 1:
The apparatus is segmented into distinct functional modules: an applying unit with its own mask stage and a cleaning unit with its own mask stage. This modular segmentation allows independent operation of each unit, improving productivity while managing complexity through functional separation rather than integration.
Solution Approach 2:
A rotation driver acts as an intermediary mechanism that automatically transfers masks between the applying unit and cleaning unit. This automated intermediary reduces the need for manual intervention and complex coordination, allowing multiple masks to be managed systematically across different units.
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
This approach improves process yield and reduces processing time by allowing multiple application processes to be performed continuously, thereby enhancing the reliability and efficiency of OLED display manufacturing.
Implementation Method 1
a first cleaning process, which cleans a second mask in a cleaning unit
Data Source
AI summary
A cover layer manufacturing method includes: a first applying process, which forms a first cover layer on a rear surface of a first display panel using a first mask in an applying unit; a first cleaning process, which cleans a second mask in a cleaning unit; a rotating process, which changes a position of the first mask and a position of the second mask using a rotation driver; a second applying process, which forms a second cover layer on a rear surface of a second display panel using the second mask in the applying unit; and a second cleaning process, which cleans the first mask in the cleaning unit. The first applying process and the first cleaning process are substantially simultaneously performed, and the second applying process and the second cleaning process are substantially simultaneously performed.