KR-20260065864-A - Device, carrier, and method for manufacturing display tiles

Abstract

The device comprises a carrier, an orifice, and a motion platform. The carrier is configured to fix a substrate. The orifice is configured to spray an aerosol jet. The motion platform is configured to move the carrier relative to the orifice to print a plurality of electrodes on the first main surface and edge surface of the substrate while the orifice sprays a continuous aerosol jet.

Inventors

• 하간, 리처드
• 허치슨, 코디 다니엘

Assignees

• 코닝 인코포레이티드

Dates

Publication Date

20260511

Application Date

20240806

Priority Date

20230906

Claims (20)

1. As a device for manufacturing display tiles, A carrier configured to fix a substrate; An orifice configured to spray an aerosol jet; and An apparatus for manufacturing a display tile, comprising a motion platform configured to move the carrier relative to the orifice to print a plurality of electrodes on the first main surface and edge surface of the substrate while the orifice sprays a continuous aerosol jet.
2. In paragraph 1, The above motion platform is a device for manufacturing display tiles, comprising a plurality of air bearings on which the carrier floats.
3. In paragraph 1, The motion platform described above is an apparatus for manufacturing display tiles, comprising a non-contact linear motor for moving the carrier relative to the orifice.
4. In paragraph 3, The motion platform above is an apparatus for manufacturing display tiles, comprising a flexure that couples the carrier to the non-contact linear motor.
5. In paragraph 1, The above motion platform is an apparatus for manufacturing display tiles, comprising a plurality of magnets for detachably coupling the carrier to the motion platform.
6. In paragraph 1, The motion platform is a device for manufacturing display tiles, configured to move the carrier along a first axis and a second axis perpendicular to the first axis.
7. In paragraph 1, An apparatus for manufacturing display tiles, further comprising an optical system configured to correct the position of the orifice whenever the orifice is replaced.
8. In Paragraph 7, The above optical system is further configured to position the substrate relative to the orifice based on a reference point on the substrate before printing the plurality of electrodes, for an apparatus for manufacturing a display tile.
9. In paragraph 1, A device for manufacturing display tiles, wherein the orifice is fixed while printing the plurality of electrodes.
10. In paragraph 1, An apparatus for manufacturing a display tile, further comprising a print head tower configured to position the orifice with respect to the substrate.
11. In Paragraph 10, The above-described print head tower is an apparatus for manufacturing display tiles, comprising a non-contact linear motor for moving the orifice relative to the substrate.
12. In Paragraph 11, The above-described print head tower is an apparatus for manufacturing display tiles, comprising a flexure that couples the orifice to the non-contact linear motor.
13. As a carrier for manufacturing display tiles, It includes a first carrier portion configured to contact a first main surface of a substrate, and the first carrier portion: A plurality of first magnets configured to detachably connect the first carrier portion to a motion platform of a device for manufacturing the display tile; and A carrier for manufacturing display tiles, comprising a plurality of second magnets configured to fix the substrate to the first carrier portion.
14. In Paragraph 13, A carrier for manufacturing a display tile, wherein the first carrier portion further comprises a plurality of first kinematic adjusters configured to adjust the position of the first carrier portion relative to the motion platform.
15. In Paragraph 13, A carrier for manufacturing a display tile, further comprising a plurality of third magnets, wherein each third magnet is configured to be arranged on a second main surface of the substrate facing the first main surface, opposite to the second magnet corresponding to the plurality of second magnets, in order to fix the substrate to the first carrier portion.
16. In Paragraph 13, It further includes a second carrier portion configured to contact a second main surface of the substrate facing the first main surface, and the second carrier portion: A plurality of third magnets facing the plurality of second magnets to fix the substrate between the first carrier portion and the second carrier portion; and A carrier for manufacturing a display tile, comprising a plurality of fourth magnets configured to detachably connect a second carrier portion to the motion platform.
17. As a method for manufacturing display tiles, Step of spraying a first continuous aerosol jet from an orifice; A step of depositing a first portion of a first electrode on a first main surface and an edge surface of a substrate from the first continuous aerosol jet sprayed from the orifice; and A method for manufacturing a display tile, comprising the step of depositing a first portion of a second electrode on the first main surface and the edge surface of the substrate from the first continuous aerosol jet sprayed from the orifice.
18. In Paragraph 17, The step of depositing the first portion of the second electrode is: After depositing a first portion of the first electrode, a step of moving the substrate out of the first continuous aerosol jet sprayed from the orifice; A step of moving the substrate relative to the orifice while the substrate is outside the first continuous aerosol jet ejected from the orifice; and A method for manufacturing a display tile, comprising the step of moving the substrate into the first continuous aerosol jet ejected from the orifice to deposit a first portion of the second electrode.
19. In Paragraph 17, The step of depositing the first portion of the second electrode is: A step of depositing a first portion of the first electrode and then moving a masked portion of the substrate into the first continuous aerosol jet sprayed from the orifice; A step of moving the substrate relative to the orifice while the masked portion of the substrate is within the first continuous aerosol jet ejected from the orifice; and A method for manufacturing a display tile, comprising the step of moving an unmasked portion of the substrate into the first continuous aerosol jet sprayed from the orifice to deposit a first portion of the second electrode.
20. In Paragraph 17, Step of flipping the substrate; A step of spraying a second continuous aerosol jet from the orifice; A step of depositing a second portion of the first electrode on a second main surface and an edge surface of the substrate from a second continuous aerosol jet ejected from the orifice, wherein the second main surface faces the first main surface and the edge surface extends between the first main surface and the second main surface; and A method for manufacturing a display tile, further comprising the step of depositing a second portion of the second electrode on the second main surface and the edge surface of the substrate from the second continuous aerosol jet sprayed from the orifice.

Description

Device, carrier, and method for manufacturing display tiles Cross-reference of related applications This application claims the benefit of priority to U.S. provisional application serial number 63/580798 filed on September 6, 2023, under 35 U.S.C. § 119, the contents of which form the basis and are incorporated herein by reference in their entirety. The present disclosure generally relates to a method and apparatus for manufacturing a substrate having a wrap-around electrode. More specifically, the present disclosure relates to a method and apparatus for manufacturing a substrate having a wrap-around electrode using an aerosol jet. Displays such as micro LED displays include borderless, bezel-free, and/or tiled displays. Top-surface emitting micro LED displays require a method to electrically interconnect the LEDs on the top surface of the substrate with a driver control board located on the back of the substrate. This can be achieved using flex connectors attached to the edges of the substrate. However, for borderless, bezel-free, and tiled displays, using flex connectors attached to the top surface of the substrate is undesirable. In such cases, the flex connectors are exposed to the viewer and must be covered by a bezel, or they occupy too much space between tiles, hindering seamless tiling. One solution for electrically connecting the top surface of the display substrate to the driver control board is to use wrap-around electrodes. Wrap-around electrodes can be fabricated at the edges of a substrate. This allows the electrode to occupy less physical space and makes it difficult to observe with the naked eye. Wrap-around electrodes have been demonstrated in borderless, bezel-free, and tiled displays. These electrodes can be composed of various materials and can be fabricated by methods including printing, vacuum deposition, flex connection, and electroplating. Methods to improve the electrical performance and reliability of wrap-around electrodes are being achieved through material and process improvements. Some embodiments of the present disclosure relate to an apparatus for manufacturing display tiles. The apparatus comprises a carrier, an orifice, and a motion platform. The carrier is configured to secure a substrate. The orifice is configured to spray an aerosol jet. The motion platform is configured to move the carrier relative to the orifice to print a plurality of electrodes on a first main surface and an edge surface of the substrate while the orifice sprays a continuous aerosol jet. Another embodiment of the present disclosure relates to a carrier for manufacturing a display tile. The carrier includes a first carrier portion configured to contact a first main surface of a substrate. The first carrier portion includes a plurality of first magnets and a plurality of second magnets. The plurality of first magnets are configured to detachably connect the first carrier portion to a motion platform of a device for manufacturing a display tile. The plurality of second magnets are configured to fix the substrate to the first carrier portion. Other embodiments of the present disclosure relate to a method for manufacturing a display tile. The method comprises the step of spraying a first continuous aerosol jet from an orifice. The method comprises the step of depositing a first portion of a first electrode on a first main surface and an edge surface of a substrate from the first continuous aerosol jet sprayed from the orifice. The method comprises the step of depositing a first portion of a second electrode on a first main surface and an edge surface of a substrate from the first continuous aerosol jet sprayed from the orifice. The apparatus and method disclosed herein enable high-volume electrode printing (e.g., high precision, high repeatability, and short stroke operation). Compared to previous solutions, the apparatus provides frictionless printing strokes, index strokes with significantly reduced friction, extended equipment life, improved accuracy (e.g., about ±5 microns), and improved printing speed. Additional features and advantages will be presented in the following detailed description, some of which will be readily apparent to those skilled in the art from such description or recognized by practicing the embodiments described herein, including the following detailed description, claims, and attached drawings. It should be understood that both the general description above and the detailed description below are merely illustrative and are intended to provide an overview or framework for understanding the nature and features of the claims. The attached drawings are included to provide further understanding and are incorporated into this specification and constitute part of it. The drawings illustrate one or more embodiments and, together with this description, explain the principles and operations of the various embodiments. FIG. 1 is a perspective view of an exemplary substrate; FIG. 2 is a per