Optical Patterning Apparatus with Diffusion Unit for Large Displays
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Solution Overview
Problem
Existing optical patterning methods face challenges in configuring equipment for large display devices due to the difficulty in maintaining uniform light distribution and the risk of window bending in vacuum chambers as the size of the mask increases, especially when numerous light sources are required to achieve a large transfer pattern.
Innovation Solution
The apparatus includes a vacuum chamber with a diffusion unit and light source units positioned outside or within the chamber, utilizing reflection units and a transmission region to ensure uniform light distribution and minimize the number of light sources, thereby reducing equipment complexity and preventing window bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If numerous light sources are installed to realize a transfer pattern to a large panel, then the light distribution coverage is improved, but the device complexity increases and maintenance difficulty increases
Solution Approach 1:
A diffusion unit is introduced as an intermediary component between the light source and the mask. The diffusion unit receives light from a reduced number of light sources and redistributes it uniformly across the large mask area, eliminating the need for numerous light sources while maintaining comprehensive light distribution coverage.
Solution Approach 2:
The diffusion unit is divided into multiple diffusion elements (such as lens arrays or micro-prisms) that independently redirect light rays. Each segment contributes to the overall uniform light distribution, allowing the system to cover large areas with fewer input light sources while maintaining manageable complexity.
2Reliability
If a thick window is used to maintain a predetermined vacuum state of the vacuum chamber, then the vacuum stability is improved, but the window may bend due to vacuum pressure
Solution Approach 1:
The light source unit is extracted from the vacuum chamber environment and positioned externally. This eliminates the need for a large transmission window in the vacuum chamber, as light can be introduced through a smaller window or even through the diffusion unit without compromising the vacuum seal. The vacuum chamber structure is simplified while maintaining vacuum stability.
3Use of energy by moving object
If the size of the window increases to allow light transmission for large masks, then the light transmission capability is improved, but the window may bend due to vacuum pressure
Solution Approach 1:
The diffusion unit serves as a mediator that can be positioned outside the vacuum chamber or through a small aperture. It receives light from external light sources and redirects it into the vacuum chamber, eliminating the need for a large transmission window. This maintains full light transmission capability while preserving window shape stability.
4Productivity
If numerous light sources are installed to achieve large transfer patterns, then the productivity is improved, but the ease of operation deteriorates due to management and maintenance difficulty
Solution Approach 1:
The diffusion unit acts as an intermediary that consolidates the function of multiple light sources into a single component system. Instead of managing numerous individual light sources, operators only need to maintain one light source unit and one diffusion unit, dramatically improving ease of operation while maintaining the capability to produce large transfer patterns.
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 configuration allows for the maintenance of uniform light distribution to the mask, facilitating the production of large optical patterns with high resolution while simplifying the management and maintenance of light sources, and preventing window bending by optimizing the placement and size of the transmission region.
Implementation Method 1
a diffusion unit adjacent the mount, spaced apart from the mount by a preset interval, and facing the mount, the diffusion unit to diffuse light incident thereon as uniform surface light
Implementation Method 2
a light source unit spaced in a lateral direction from the diffusion unit, the light source unit to generate light to be incident on the diffusion unit
Implementation Method 3
a first reflection unit at a preset angle in a light transmission path between the light source unit and the diffusion unit, the first reflection unit to supply light transmitted from the light source unit to the diffusion unit
Implementation Method 4
an auxiliary chamber adjacent the vacuum chamber, wherein the first reflection unit, the light source unit, and the diffusion unit are within the auxiliary chamber
Data Source
AI summary
An apparatus for forming an optical pattern includes a vacuum chamber, a mount on which a substrate to be prepared using a mask is to be supported, a diffusion unit adjacent the mask, spaced apart from the mask by a preset interval, and facing the mask, the diffusion unit to diffuse light incident thereon as uniform surface light and transmit the uniform surface light to the mask, and a light source unit spaced in a lateral direction from the diffusion unit, the light source unit to generate light to be incident on the diffusion unit.