Upward-Facing Adhesive Ejection Head for Uniform Display Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for applying optically clear adhesive (OCA) to display panels struggle with achieving uniform thickness and avoiding contamination of the adhesive on non-application surfaces, particularly when the panel has openings or notches, which can lead to inefficiencies and material waste.
Innovation Solution
An apparatus and method using an ejection head with an upward-facing outlet and a light irradiation unit that moves in coordination to apply adhesive material uniformly on the display panel, while avoiding contamination by moving against gravity and using a roller to control viscosity, and light to temporarily cure the adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive material is applied using conventional inkjet equipment or roller, then the application process is simple, but the adhesive thickness is not uniform and contamination occurs on non-application surfaces
Solution Approach 1:
The ejection head is inverted with the ejection outlet facing upward instead of downward, allowing adhesive to be ejected upward against gravity. This inversion enables precise thickness control through gravity assistance during the lamination process while preventing contamination on non-application surfaces.
Solution Approach 2:
The ejection head divides the adhesive application into multiple ejection outlets arranged in a matrix pattern, allowing selective ejection to different regions of the display panel. This segmentation enables precise control over where adhesive is applied, preventing contamination while maintaining uniform thickness.
2Object-affected harmful factors
If adhesive is applied on upward-facing surface, then contamination of stage and side surfaces is prevented, but application process becomes more complex
Solution Approach 1:
The stage is made rotatable to dynamically change the orientation of the display panel from horizontal to vertical position. This dynamic adjustment allows the adhesive application to occur on an upward-facing surface, preventing contamination while the stage returns to horizontal position after application.
Solution Approach 2:
The display panel is rotated to a vertical position with the application surface facing upward before adhesive ejection begins. This preliminary positioning ensures that adhesive is ejected onto an upward-facing surface, preventing contamination from occurring during the application process.
3Manufacturing precision
If ejection head moves in second direction intersecting first direction, then adhesive can be applied uniformly across panel, but coordination with light irradiation unit becomes complex
Solution Approach 1:
The ejection head and light irradiation unit are integrated into a single coordinated system that moves together in the second direction. This merging ensures that adhesive ejection and UV curing occur simultaneously at the same location, maintaining uniform thickness while simplifying coordination through integrated control.
Solution Approach 2:
The ejection head and light irradiation unit move continuously in the second direction during adhesive application, ensuring uninterrupted adhesive ejection and immediate UV curing. This continuous action maintains uniform thickness across the entire display panel surface.
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 the application of OCA to a uniform thickness on display panels with various shapes, including those with openings, preventing contamination of the stage and side surfaces, thereby improving manufacturing efficiency and reducing waste.
Implementation Method 1
a light irradiation unit which applies light toward a bottom surface of the stage
Implementation Method 2
a heat unit disposed in the body part to surround the stirring part
Data Source
AI summary
An apparatus and method for manufacturing a display device are provided. The apparatus for manufacturing the display device, includes: a stage, and an ejection head including an ejection outlet, which is open upward in a first direction opposite to a direction of gravity. The ejection head is configured to move in a second direction, which intersects the first direction, and disposed under the stage in the direction of the gravity. The ejection head includes a body part, which contains an adhesive material, and a stirring part, which is disposed in the body part and includes a roller, which rotates a predetermined number of times per unit time to control viscosity of the adhesive material.