UV Mask Replacement in LED Packaging via Segmented Chambers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing ultraviolet irradiation devices for packaging light-emitting diodes require extensive time to recover the N2 environment during UV mask replacement, leading to significant productivity losses due to the lengthy process of restoring the nitrogen atmosphere.
Innovation Solution
The ultraviolet irradiation device features a closed shell with a movable UV mask and a delivery unit comprising rolling units and gate mechanisms, allowing for rapid mask replacement and stabilization, along with an air exhaust and nitrogen filling system to maintain a nitrogen environment within 20-30 minutes, significantly reducing the time needed for mask changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the UV mask is replaced in the existing ultraviolet irradiation device, then the mask can be changed to accommodate different production requirements, but the N2 environment must be destroyed and recovered which takes more than 6 hours, significantly reducing productivity
Solution Approach 1:
The device is divided into two independent chambers: a first chamber for holding the OLED panel and a second chamber for storing and replacing UV masks. This segmentation allows mask replacement to occur in the second chamber without affecting the N2 environment in the first chamber, thereby enabling rapid mask exchange while maintaining production continuity and avoiding the 6+ hour environment recovery time.
Solution Approach 2:
A transfer mechanism serves as an intermediary between the two chambers, enabling the UV mask to be moved from the second chamber to the first chamber without direct human intervention that would compromise the N2 environment. This intermediary transfer system allows the N2 environment to be maintained while still enabling mask replacement.
2Ease of operation
If the chamber is opened to replace the UV mask, then the mask can be exchanged, but the N2 environment is destroyed and must be recovered by inflating N2, taking more than 6 hours
Solution Approach 1:
The device is divided into two independent chambers: a first chamber for holding the OLED panel and a second chamber for storing and replacing UV masks. This segmentation allows mask replacement to occur in the second chamber without affecting the N2 environment in the first chamber, thereby enabling rapid mask exchange while maintaining production continuity and avoiding the 6+ hour environment recovery time.
Solution Approach 2:
The second chamber is pre-prepared with UV masks stored in a controlled environment. When mask replacement is needed, the new mask is already ready in the second chamber, eliminating the need to open the first chamber and disrupt the N2 environment for mask preparation and exchange.
3Reliability
If a UV mask is arranged on a pin and a UV lamp is arranged below it, then the UV curing process can be performed, but the entire chamber must be opened for mask replacement, causing significant downtime
Solution Approach 1:
The device is divided into two independent chambers: a first chamber for holding the OLED panel and a second chamber for storing and replacing UV masks. This segmentation allows mask replacement to occur in the second chamber without affecting the N2 environment in the first chamber, thereby enabling rapid mask exchange while maintaining production continuity and avoiding the 6+ hour environment recovery time.
Solution Approach 2:
While UV masks are being replaced in the second chamber, the first chamber maintains its N2 environment and can continue processing. This allows the useful action of UV curing to continue uninterrupted in the first chamber while mask maintenance occurs in parallel in the second chamber, maximizing overall system productivity.
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 solution enables rapid UV mask replacement, saving time and improving productivity by minimizing the duration required to restore a nitrogen environment, thus enhancing the efficiency of the packaging process.
Implementation Method 1
a UV lamp, which is arranged below the UV mask
Implementation Method 2
a first rolling unit configured to deliver the light-emitting diode is arranged in the chamber
Data Source
AI summary
Disclosed is an ultraviolet irradiation device for package of a light-emitting diode. The ultraviolet irradiation device includes a sealed shell. A light-emitting diode to be packaged is arranged in the shell, and a UV mask that is movable in the shell is arranged below the light-emitting diode. The ultraviolet irradiation device further includes a UV lamp arranged below the UV mask. The ultraviolet irradiation device further includes a sealed chamber which is in communication with the shell. The chamber is arranged at a side of the shell. A first rolling unit that is configured to deliver the light-emitting diode is arranged in the chamber, and a first gate and a second gate are respectively arranged at two ends of the chamber. The chamber is further in communication with an air exhaust unit and a first gas source respectively. The structure of the ultraviolet irradiation device is simple. When a replacement of the UV mask is performed, a rapid replacement thereof can be achieved, i.e., much time for replacing the UV mask can be saved, which is beneficial for improving productivity.