Optical Fume-Sensing Suction Head for Display Substrate Cutting
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Solution Overview
Problem
During the cutting process of a cell-based substrate to form a display panel, fine particles or fumes are generated, which can be adsorbed by the pad portion, leading to contact failures and display defects.
Innovation Solution
An apparatus is employed that includes a suction unit with a light emitting and receiving system to quantify fume generation, adjusting air injection and negative pressure based on fume levels to effectively remove fumes during laser processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser processing is used to cut the substrate, then cutting precision is improved, but fume generation increases causing contact failures
Solution Approach 1:
The patent installs optical sensors (light emitting units and light receiving units) around the suction unit to detect fumes generated during laser cutting. The sensors measure light blockage caused by fumes and convert this harmful effect into useful information for controlling the suction unit, thereby resolving the contradiction between maintaining cutting precision and managing fume generation
2Reliability
If uniform suction is applied across the entire substrate area, then fume removal is maintained, but energy consumption increases
Solution Approach 1:
The patent divides the substrate processing area into multiple regions, each equipped with optical sensors and controlled by the controller. The controller adjusts suction intensity locally based on real-time fume detection in each region, applying stronger suction only where fumes are detected and reducing or stopping suction in clean areas, thereby maintaining effective fume removal while reducing overall energy consumption
3Productivity
If real-time fume detection is implemented, then fume removal efficiency is improved, but device complexity increases
Solution Approach 1:
The patent integrates optical sensors (light emitting units and light receiving units) into the existing suction unit structure, making the suction unit serve dual functions: both suction and fume detection. The controller centralizes the logic for coordinating suction control across multiple regions, reducing overall system complexity while enabling real-time fume detection and responsive suction adjustment
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 enables real-time, quantitative measurement and removal of fumes, preventing display defects by ensuring effective fume management during substrate cutting.
Implementation Method 1
a light emitting unit disposed on at least one inner surface of the outer box to provide light, and a light receiving unit disposed opposite to the light emitting unit, and disposed on at least one inner surface of the outer box, the light receiving unit receiving the light provided from the light emitting unit
Implementation Method 2
an air blower that sprays air toward the stage, the air blower being coupled to the main body
Implementation Method 3
a suction unit positioned above the stage... The suction unit may include a suction part providing a negative pressure to the target substrate
Data Source
AI summary
According to an embodiment, an apparatus for manufacturing a display device includes a stage on which a target substrate is mounted, and a suction unit positioned above the stage. The suction unit includes a main body including an outer box with top and bottom openings and an inner cup disposed in the outer box, a light emitting unit disposed on at least one inner surface of the outer box, the light emitting unit providing light, and a light receiving unit disposed opposite to the light emitting unit, and disposed on at least one inner surface of the outer box, the light receiving unit receiving the light provided from the light emitting unit.