OLED Sealing Inspection via Dark-Field Imaging
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Solution Overview
Problem
The manufacturing process of OLED displays faces challenges in evaluating the sealing effectiveness of sealed areas, leading to errors and defects during the curing and transportation of OLED displays, which affects the lifespan and light efficiency of the elements.
Innovation Solution
A sealing inspection device and method that includes a scan unit to detect defective regions and a photographing unit with a measuring camera equipped with a dark-field illumination member to generate images and measure the effective sealing width of the sealed area, allowing for efficient inspection and evaluation of the sealing effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing member is coated and cured in OLED manufacturing, then encapsulation is achieved to prevent moisture permeation, but errors and defects are generated during curing and transportation
Solution Approach 1:
The patent performs sealing inspection before final assembly and transportation by measuring the effective sealing width of the sealed area. This preliminary detection allows defects to be identified early in the manufacturing process, preventing errors from propagating to later stages during curing and transportation.
Solution Approach 2:
The patent replaces manual visual inspection with an automated optical measurement system that uses cameras and image processing to detect and measure the sealing width. This substitution provides objective, precise measurements and eliminates human error in evaluating sealing effectiveness.
2Measurement precision
If traditional inspection methods are used for sealed area, then inspection process is simple, but measurement precision of sealing width is insufficient
Solution Approach 1:
The patent introduces an intermediary measurement system that captures images of the sealed area and processes them to calculate the effective sealing width. This intermediary layer between the sealed area and the final evaluation enables precise measurement without requiring direct physical contact or complex measurement apparatus.
Solution Approach 2:
The patent creates a digital copy of the sealed area through imaging and uses this copy for measurement and analysis. By working with the image data rather than the physical sealed area directly, the system achieves precise measurements while maintaining operational simplicity.
3Reliability
If no sealing inspection is performed, then manufacturing process is fast, but defects in sealed state OLED display are not detected
Solution Approach 1:
The inspection system is integrated into the existing manufacturing flow, allowing the sealed area to be inspected automatically as part of the production process. The system uses standard imaging components and automated image processing to perform inspection without requiring separate manual evaluation steps, thus maintaining manufacturing speed while improving reliability.
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 solution enables precise measurement and inspection of the sealed area, detecting defective regions and determining the effective sealing width, thereby improving the quality and reliability of OLED displays by ensuring effective encapsulation and preventing moisture and oxygen ingress.
Implementation Method 1
The measuring camera may include a dark-field illumination member... The plurality of point light sources may respectively emit light obliquely with reference to a facing direction of the microscope lens
Data Source
AI summary
A sealing inspection device includes a scan unit through which a display device substrate including a top plate coupled to a bottom plate by a sealing member in the sealed area passes; and a photographing unit through which the display device substrate which has passed through the scan unit, further passes. The scan unit generates coordinate values of the sealed area of the display device substrate, detects a defective region in the sealed area of the display device substrate, and includes a plurality of scan cameras. The photographing unit generates an image of the sealed area of the display device substrate using the generated coordinate values, measures an effective sealing width of the sealed area using the generated image, and comprises a measuring camera.