Pattern-Electrode Loading Plate for Uniform Display Coating
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Solution Overview
Problem
Existing methods for fabricating display panels face issues with the uniformity of coating materials due to differences in surface energy between the loading plate and the fabrication substrate, leading to non-uniform thin film formation and potential image display defects.
Innovation Solution
An apparatus with a loading plate featuring pattern electrodes and a thin-film coating controller that applies a high-level pattern voltage to selectively form a uniform thin film by manipulating the electric field between electrodes, based on substrate characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coating materials are dispensed onto the fabrication substrate using a dispenser or inkjet printer, then the materials can be applied to the substrate, but the uniformity of leveling of the coating materials deteriorates due to differences in surface energy between the loading plate and the fabrication substrate
Solution Approach 1:
The patent applies a preliminary action by forming a leveling layer between the fabrication substrate and the loading plate before dispensing the coating materials. This leveling layer is created in advance to compensate for surface energy differences and substrate irregularities, ensuring uniform material distribution during the subsequent coating process. The leveling layer acts as an intermediate medium that pre-establishes the necessary surface properties for uniform coating.
Solution Approach 2:
The patent introduces an intermediary element - the leveling layer - that mediates between the loading plate and the fabrication substrate. This leveling layer serves as a buffer that eliminates the harmful effect of surface energy differences between the loading plate and substrate, as well as compensating for substrate irregularities. The intermediary layer transfers the coating materials uniformly without being directly affected by the surface energy mismatch.
2Manufacturing precision
If coating materials are applied on the fabrication substrate, then the materials can be deposited, but the formation of uniformly leveled thin film deteriorates due to irregularities of the fabrication substrate
Solution Approach 1:
The patent performs a preliminary action by creating a leveling layer that compensates for substrate irregularities before the coating materials are applied. This leveling layer is formed in advance to create a uniform surface topology, ensuring that subsequent coating materials are deposited evenly across the entire substrate area regardless of underlying irregularities.
Solution Approach 2:
The leveling layer acts as an intermediary between the irregular substrate surface and the coating materials. It absorbs and compensates for the harmful effects of substrate irregularities, providing a uniform interface for material deposition. The intermediary layer ensures that the coating process is not directly influenced by substrate topography variations.
3Productivity
If photoresist or insulating materials are dispensed and printed on the fabrication substrate, then the fabrication process can proceed, but image display defects occur due to non-uniform thin film formation
Solution Approach 1:
The patent implements a preliminary action by forming the leveling layer before dispensing the photoresist or insulating materials. This pre-formed leveling layer ensures that subsequent coating operations produce uniform thin films, preventing image display defects while maintaining continuous fabrication process operation. The leveling layer is prepared in advance to eliminate potential quality issues before they occur during the main fabrication process.
Solution Approach 2:
The leveling layer serves as an intermediary that protects the final product quality by compensating for substrate irregularities during the fabrication process. It ensures uniform material distribution and thin film formation, thereby maintaining both productivity and reliability. The intermediary layer prevents defects from propagating through the fabrication process, ensuring high-quality output without interrupting production flow.
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
Improves fabrication quality by ensuring uniform thin film formation, reduces image display defects, and enhances production efficiency by minimizing the impact of substrate irregularities.
Implementation Method 1
a thin-film coating controller disposed on a rear surface of the loading plate and connected to the plurality of pattern electrodes to supply a high-level pattern voltage to at least one pattern electrode among the plurality of pattern electrodes so that an electric field is formed between the plurality of pattern electrodes
Data Source
AI summary
An apparatus for fabricating a display device is provided which comprises a loading plate having a plurality of pattern electrodes arranged in a matrix on a front surface, wherein a fabrication substrate is loaded on the front surface where the plurality of pattern electrodes is arranged, a dispenser for dispensing a liquid dispensing material on the fabrication substrate, and a thin-film coating controller disposed on a rear surface of the loading plate and connected to the plurality of electrodes to supply a high-level pattern voltage to at least one pattern electrode among the plurality of pattern electrodes so that an electric field is formed between the plurality of pattern electrodes, wherein the thin-film coating controller selectively supplies the high-level pattern voltage to the at least one pattern electrode based on pattern information including a type of the dispensing material, a pattern design structure, or a step structure of the fabrication substrate.