Staged Movement System for Uniform Quantum Dot Distribution
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Solution Overview
Problem
The existing manufacturing processes for display apparatuses often result in visual defects such as stripes due to uneven distribution of materials, particularly when quantum dots and scatterers are applied using inkjet printing, leading to inconsistent concentrations and potential stains.
Innovation Solution
The use of a staged movement system for the substrate, where the stage is moved in multiple directions to align the discharge nozzles with coating regions in a way that only specific nozzles continuously discharge droplets, ensuring uniform distribution of quantum dots and scatterers, and the application of titanium oxide as a scatterer to enhance color conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If droplets are supplied to correspond to each pixel using inkjet printing, then material distribution can be achieved, but visual defects such as stripes and stains occur due to uneven concentration
Solution Approach 1:
The substrate is divided into multiple coating regions, and the discharge part is divided into multiple nozzles. Each nozzle is assigned to discharge droplets to a specific coating region, enabling localized control of material distribution and preventing concentration variations that cause visual defects.
Solution Approach 2:
The stage and discharge part are designed to move relative to each other in a controlled manner. The stage moves in a first direction while the discharge part moves in a second direction, allowing dynamic adjustment of nozzle-to-region alignment and ensuring uniform droplet distribution across the substrate.
2Area of stationary object
If the discharge part supplies droplets to all coating regions continuously, then complete coverage is achieved, but material concentration becomes inconsistent across regions
Solution Approach 1:
Different nozzles are assigned to different coating regions based on their spatial positions. Each nozzle discharges droplets only to its corresponding coating region, ensuring that material concentration is optimized locally for each region while achieving complete overall coverage.
Solution Approach 2:
The control unit coordinates the movement of the stage and discharge part based on the relative positions of nozzles and coating regions. This feedback mechanism ensures that each nozzle remains aligned with its target coating region, maintaining consistent material concentration across all regions.
3Productivity
If the stage moves continuously in one direction, then manufacturing efficiency is improved, but alignment precision between nozzles and coating regions deteriorates
Solution Approach 1:
The system employs dynamic coordination between stage movement in the first direction and discharge part movement in the second direction. This two-dimensional dynamic adjustment allows the system to maintain precise nozzle-to-region alignment while continuously processing large substrate areas, thereby preserving both efficiency and precision.
Solution Approach 2:
The alignment problem is solved by introducing a second dimension of movement. While the stage moves in the first direction for continuous processing, the discharge part moves in the second direction to compensate for positional deviations, ensuring precise alignment without sacrificing manufacturing efficiency.
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 method prevents the formation of visual defects like stains and ensures uniform material distribution, improving the color purity and display quality of the display apparatus by maintaining consistent scatterer concentrations across the substrate.
Implementation Method 1
supplying droplets onto the substrate by a discharge part
Implementation Method 2
The droplets may include a scatterer... application of titanium oxide as a scatterer to enhance color conversion efficiency
Data Source
AI summary
An apparatus for manufacturing a display apparatus includes a stage on which a substrate is disposed, a first driver that moves the stage in a first direction, a second driver connected to the first driver and moving the first driver in a second direction, and a discharge part facing the stage and supplying droplets to the substrate. The second driver moves the stage by a multiple of a natural number of 1 or more of a distance between pixels arranged on the substrate.