UV Curing Resin Layer Profile Control

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Solution Overview

Problem

Existing methods for forming resin layers using ultraviolet curable materials in display device processes face challenges in achieving uniformity and reducing unevenness, particularly in the curing process.

Innovation Solution

A method and apparatus that selectively apply and cure ultraviolet ray curable materials by adjusting the shape and amount of light of first and second ultraviolet rays, allowing for partial curing of a preliminary resin layer before complete curing, using a digital light source processing module and multiple light sources to control the curing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If ultraviolet ray curable material is applied and cured using conventional methods, then the resin layer can be formed, but uniformity is poor and unevenness is significant

Engineering Contradiction:

Improveuniformity of resin layerVSAvoidcuring process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The curing process is divided into multiple stages with different ultraviolet light sources. A first ultraviolet light source performs preliminary curing, and a second ultraviolet light source performs complete curing. This segmentation allows different regions of the resin layer to be cured under different conditions, improving uniformity while managing process complexity through staged implementation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different ultraviolet light sources with different characteristics are applied to different portions of the resin layer. The first ultraviolet light source has specific characteristics suitable for preliminary curing of certain areas, while the second ultraviolet light source has different characteristics for complete curing. This local differentiation optimizes curing quality in each region, addressing uniformity issues.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If the entire resin layer is cured simultaneously, then the process is simple, but the cross-sectional profile cannot be adjusted and uniformity is poor

Engineering Contradiction:

Improvecross-sectional profile controlVSAvoidcuring process structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The curing process is segmented into preliminary curing and complete curing stages using different ultraviolet light sources. This allows the cross-sectional profile to be adjusted by controlling which regions receive which light source, enabling precise control over the resin layer structure while managing complexity through functional separation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The curing process is made dynamic by allowing selective application of different ultraviolet light sources to different regions at different stages. The system can adaptively control which areas are preliminarily cured and which are completely cured, enabling adjustment of the cross-sectional profile based on specific manufacturing requirements.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If conventional single-stage curing is used, then the process is simple, but unevenness in the resin layer cannot be reduced

Engineering Contradiction:

Improveevenness of resin layerVSAvoidcuring process efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The curing process is divided into preliminary curing and complete curing stages. By segmenting the process, the system can address unevenness by applying different curing conditions to different regions, improving overall uniformity while maintaining productivity through efficient staged curing rather than requiring complex single-stage processes.

Inventive Principle:

Principle #1Segmentation

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 approach enables the adjustment of the resin layer's cross-sectional profile, improves uniformity, and reduces unevenness, resulting in a more consistent resin layer formation.

Implementation Method 1

selectively curing a preliminary resin layer by irradiating at least a portion of an entire area of the preliminary resin layer formed of the ultraviolet ray curable material with first ultraviolet rays whose shape and amount of light are adjusted

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

completely curing the preliminary resin layer by irradiating second ultraviolet rays having a different amount of light from the first ultraviolet rays whose shape and amount of light are adjusted

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS20240026105A1Method for forming a resin layer and an apparatus for forming the resin layer used therein

Publication Date: 2024.01.25 SAMSUNG DISPLAY CO LTD

AI summary

A method for forming a resin layer, the method including selectively applying an ultraviolet ray curable material that reacts to ultraviolet rays on a target substrate, selectively curing a preliminary resin layer by irradiating at least a portion of an entire area of the preliminary resin layer formed of the ultraviolet ray curable material with first ultraviolet rays whose shape and amount of light are adjusted, and completely curing the preliminary resin layer by irradiating second ultraviolet rays having a different amount of light from the first ultraviolet rays whose shape and amount of light are adjusted.