Thermal Wave Inspection for Display Panel Crack Detection
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Solution Overview
Problem
Display panels, particularly those undergoing deposition and photolithography processes, often develop defects like cracks during manufacturing, which are difficult to detect effectively using existing methods.
Innovation Solution
An apparatus that uses a laser excitation unit to irradiate a non-display area of the display panel with a point laser beam, generating thermal waves, which are then measured by a thermal wave detecting unit to create images, allowing for non-contact detection of cracks through a controlled system that includes a driving unit for positioning and a suction pump for panel fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods are used to detect cracks in display panels, then the inspection process is simple, but the detection accuracy is insufficient
Solution Approach 1:
The patent replaces conventional mechanical or optical contact inspection methods with a thermal wave-based non-contact detection system. A laser irradiates the display panel to generate thermal waves, and a detector measures these thermal waves to identify cracks, thereby achieving high detection accuracy without mechanical contact or complex optical alignment systems.
Solution Approach 2:
The patent utilizes changes in thermal parameters (temperature distribution and thermal wave propagation) to detect cracks. By irradiating the panel with a laser and measuring the resulting thermal wave patterns, the system transforms the invisible crack structure into detectable thermal signatures, enabling accurate defect identification through parameter transformation.
2Object-affected harmful factors
If contact-based inspection methods are used, then the equipment is simple, but the inspection process may damage the panel
Solution Approach 1:
The patent replaces mechanical contact inspection with a non-contact thermal wave detection system. The laser irradiates the panel surface without physical contact, and the thermal wave detector measures the resulting thermal patterns from a distance, completely eliminating the risk of mechanical damage while maintaining high detection precision for cracks and defects.
3Productivity
If traditional visual inspection is used, then the system is simple, but the inspection efficiency is low
Solution Approach 1:
The patent replaces manual visual inspection with an automated thermal wave detection system. The laser automatically scans the panel surface, the detector continuously measures thermal wave patterns, and the system processes the data to identify defects, dramatically increasing inspection efficiency and throughput while using sophisticated but integrated detection equipment.
Solution Approach 2:
The patent implements continuous laser scanning and continuous thermal wave measurement across the entire panel surface. This uninterrupted inspection process eliminates the intermittent nature of manual inspection, maintaining constant detection capability and significantly improving productivity through sustained automated operation.
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
Enables accurate and non-contact detection of cracks in display panels, enhancing defect inspection efficiency and reliability by visualizing thermal wave patterns to identify defects within the panel's structure.
Implementation Method 1
A laser excitation unit is configured to irradiate the non-display area with a point laser beam
Implementation Method 2
A thermal wave detecting unit is configured to measure a thermal wave generated from the non-display area and generate a plurality of thermal wave images of irradiated portions of the non-display area
Implementation Method 3
A suction pump is configured to suction air through the suction hole to fix the display panel to the table
Data Source
AI summary
An apparatus for inspecting a display panel for defects includes a table which supports the display panel, a laser excitation unit that irradiates a non-display area of the display panel with a point laser beam, a thermal wave detecting unit that generates thermal wave images of irradiated portions of the non-display area, a driving unit, and a control unit. A groove corresponding to an edge of the display panel may be defined in a top surface of the table. A defect, such as a crack, may be detected by comparing a defect pattern obtained from the thermal wave images with a pre-registered defect pattern.