OLED metal mask roll-to-roll line production speed compensation method

Abstract

This invention provides a method for speed compensation in roll-to-roll production of OLED metal masks, relating to the technical field of wet etching. The method includes the following steps: obtaining the etching rate A1 and ramp-up speed S1 of the preceding batch of the first master roll; obtaining the etching rate A2 of the preceding batch of the second master roll; the ramp-up speed S2 of the second master roll, connected after the first master roll, is: S2 = K1 * S1, where K1 is an adjustment coefficient. This achieves the technical effect that the product does not need to undergo first-article testing again before roll-to-roll production.

Description

Technical Field

[0001] This invention relates to the field of wet etching technology, and more specifically, to a method for speed compensation in the production of OLED metal mask roll-to-roll lines. Background Technology

[0002] Many of the film structures in an Organic Light-Emitting Diode (OLED) are formed by vapor deposition using a Metal Mask Assembly (MFA). A complete MFA typically consists of a mask frame, a fine metal mask (FMM), and an alignment mask. The quality of the fine metal mask (FMM) plays a decisive role in the vapor deposition effect of the film structures.

[0003] Roll-to-roll etching of OLED metal masks is a high-precision, highly automated chemical etching method. It can achieve fully automated continuous etching of the entire roll for flexible rolled materials such as stainless steel and copper. There is no need for manual board joining and unloading at the front and rear. The mechanical automated roll-to-roll transfer operation between processes is convenient for mass etching production and is more suitable for mass production, resulting in more stable products.

[0004] However, in the roll-to-roll manufacturing industry, wet etching is affected by chemicals, equipment, and etching barriers, resulting in fluctuating etching rates and inconsistent performance between different products. Before etching, a first piece test is usually conducted using a substrate with a shorter length than the master roll to confirm the production line speed conditions of the master roll. This process affects the product production cycle due to the time required for the first piece test.

[0005] Especially when producing the same product from roll to roll, a first-piece test is still required for subsequent production to determine the line speed of the mother roll. The first-piece test is time-consuming and tedious, requiring staff to repeatedly stop the machine and operate it. The same operation is required for both the front and back rolls, which is laborious and time-consuming. Summary of the Invention

[0006] The purpose of this invention is to provide a speed compensation method for OLED metal mask roll-to-roll production lines, so as to alleviate the technical problem that the products need to be re-tested before roll-to-roll production in the prior art.

[0007] In a first aspect, embodiments of the present invention provide a method for compensating the production speed of an OLED metal mask roll-to-roll line, comprising the following steps: Obtain the etching rate A1 and ramp-up line speed S1 of the previous batch of master rolls of the first master roll; Obtain the etching rate A2 of the previous batch of master rolls for the second master roll; The ramp-up line speed S2 of the second master roll connected after the first master roll is: S2 = K1*S1, where K1 is an adjustment coefficient.

[0008] In conjunction with the first aspect, the present invention provides a possible implementation of the first aspect, wherein the adjustment coefficient K1 = A2 / A1.

[0009] In conjunction with the first aspect, the present invention provides a possible implementation of the first aspect, wherein the first master roll and the second master roll are different products.

[0010] In conjunction with the first aspect, the present invention provides a possible implementation of the first aspect, wherein the above-mentioned OLED metal mask roll-to-roll production speed compensation method further includes a third master roll, and the etching rate A3 of the previous batch of master rolls of the third master roll is obtained; the ramp-up line speed S3 of the third master roll connected to the second master roll after etching is: S3 = K2*S2, where K2 is an adjustment coefficient.

[0011] In conjunction with the first aspect, the present invention provides a possible implementation of the first aspect, wherein the adjustment coefficient K2 = A3 / A2.

[0012] In conjunction with the first aspect, the present invention provides a possible implementation of the first aspect, wherein the second master roll and the third master roll are different products.

[0013] In conjunction with the first aspect, the present invention provides a possible implementation of the first aspect, wherein, when the etching pool lengths are inconsistent, the rate of increase S is recalculated. 1修 S 1修 = S1*L2 / L1; Where L1 is the etching pool length of the previous batch of master rolls, and L2 is the etching pool length of the current production equipment.

[0014] In conjunction with the first aspect, the present invention provides a possible implementation of the first aspect, wherein an ion sensor for stabilizing the concentration of the etching solution is provided in the etching pool.

[0015] In conjunction with the first aspect, the present invention provides a possible implementation of the first aspect, wherein test patterns for calculating etching rates are provided on both sides of the aforementioned master roll.

[0016] In conjunction with the first aspect, the present invention provides one possible implementation of the first aspect, wherein the etching rate A = D / T; Where D is the thinning amount of the master roll, and T is the ratio of the etching groove length to the transmission linear speed.

[0017] Beneficial effects: This invention provides a method for speed compensation in the production of OLED metal mask roll-to-roll lines, comprising the following steps: obtaining the etching rate A1 and ramp-up speed S1 of the previous batch of the first master roll; obtaining the etching rate A2 of the previous batch of the second master roll; the ramp-up speed S2 of the second master roll connected after the first master roll during etching is: S2 = K1*S1, where K1 is an adjustment coefficient.

[0018] Specifically, by adopting the speed compensation method for OLED metal mask roll-to-roll production, when producing products that have already been produced in roll-to-roll production, it is not necessary to retest the first piece of each roll of roll-to-roll production before mass production, thereby reducing the production cycle and increasing process output. Detailed Implementation

[0024] This embodiment provides a method for compensating the production speed of OLED metal mask roll-to-roll production lines, including the following steps: obtaining the etching rate A1 and ramp-up speed S1 of the previous batch of the first master roll; obtaining the etching rate A2 of the previous batch of the second master roll; the ramp-up speed S2 of the second master roll connected after the first master roll during etching is: S2 = K1*S1, where K1 is an adjustment coefficient.

[0025] Wherein, the adjustment coefficient K1 = A2 / A1.

[0026] The first master roll and the second master roll are different products.

[0027] Specifically, by adopting the speed compensation method for OLED metal mask roll-to-roll production, when producing products that have already been produced in roll-to-roll production, it is not necessary to retest the first piece of each roll of roll-to-roll production before mass production, thereby reducing the production cycle and increasing process output.

[0028] It should be noted that the OLED metal mask roll-to-roll production speed compensation method provided in this embodiment is used for the re-production of master rolls that have already been produced, and the re-production of multiple master rolls in a roll-to-roll manner can greatly improve production efficiency.

[0029] When the number of roll-to-roll connections exceeds two rolls, the ramp-up line speed of the third roll is calculated based on the second roll, and so on for subsequent rolls. Specifically, the roll-to-roll production speed compensation method for OLED metal mask panels also includes a third master roll, obtaining the etching rate A3 of the previous batch of master rolls for the third master roll; the ramp-up line speed S3 of the third master roll connected to the second master roll during etching is: S3 = K2 * S2, where K2 is an adjustment coefficient.

[0030] Wherein, the adjustment coefficient K2 = A3 / A2.

[0031] The second and third master rolls are for different products.

[0032] In an optional embodiment, when the etching pool lengths are inconsistent, the scaling-up linear velocity S is recalculated. 1修 S 1修 = S1*L2 / L1; Where L1 is the etching pool length of the previous batch of master rolls, and L2 is the etching pool length of the current production equipment.

[0033] In an optional embodiment, an ion sensor for stabilizing the concentration of the etching solution is provided in the etching pool.

[0034] In an optional embodiment, test patterns for calculating etching rates are provided on both sides of the master roll.

[0035] In the optional scheme of this embodiment, the etching rate A = D / T; where D is the thinning amount of the master roll and T is the ratio of the etching groove length to the transmission linear speed.

[0036] It should be noted that in existing technologies, before ramping up production of previously produced master rolls, a test piece is required. Specifically, before etching, a test piece is performed using a substrate with a shorter length than the master roll to confirm the ramp-up line speed. This process is required for each master roll in roll-to-roll production, which is time-consuming and labor-intensive. Using the OLED metal mask roll-to-roll production speed compensation method provided in this embodiment, when producing previously produced master rolls, workers only need to record the ramp-up and etching rates of the previous batch. Subsequent production runs only require calculation to obtain the ramp-up rate for roll-to-roll production.

[0037] For example, in continuous roll-to-roll production of three master rolls, the three master rolls are different products. In the existing technology, the first piece test needs to be performed on each of the three master rolls. That is, the first master roll is tested first, and then the ramp-up line speed is confirmed and ramp-up production is carried out. Then the second master roll is tested first, and then the ramp-up line speed is confirmed and ramp-up production is carried out. The same process is repeated for the third master roll, which leads to low production efficiency. The OLED metal mask roll-to-roll production speed compensation method provided in this embodiment obtains the ramp-up speed and etching rate of the previous batch when producing the first roll of master roll (the ramp-up speed is adjusted accordingly when the etching pool length changes), and directly produces the roll at this ramp-up speed (with the same etching pool conditions). Then, according to S2 = A2 / A1*S1, the ramp-up speed of the second roll of master roll is obtained, and it is also directly produced. The ramp-up speed of the third roll of master roll is obtained according to S3 = A3 / A2*S2, and it is directly produced. Thus, each roll of master roll that does not need to be produced before ramp-up can be retested for the first piece, reducing the production cycle and increasing process output.

[0038] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for speed compensation in OLED metal mask roll-to-roll production lines, characterized in that, Includes the following steps: Obtain the etching rate A1 and ramp-up line speed S1 of the previous batch of master rolls of the first master roll; Obtain the etching rate A2 of the previous batch of master rolls for the second master roll; The ramp-up line speed S2 of the second master roll connected after the first master roll is: S2 = K1*S1, where K1 is an adjustment coefficient.

2. The OLED metal mask roll-to-roll production speed compensation method according to claim 1, characterized in that, Adjustment coefficient K1 = A2 / A1.

3. The OLED metal mask roll-to-roll production speed compensation method according to claim 2, characterized in that, The first master roll and the second master roll are different products.

4. The OLED metal mask roll-to-roll production speed compensation method according to claim 1, characterized in that, It also includes a third master roll, and obtains the etching rate A3 of the previous batch of master rolls of the third master roll; the production rate S3 of the third master roll connected to the second master roll after etching is: S3 = K2*S2, where K2 is an adjustment coefficient.

5. The OLED metal mask roll-to-roll production speed compensation method according to claim 4, characterized in that, Adjustment coefficient K2 = A3 / A2.

6. The OLED metal mask roll-to-roll production speed compensation method according to claim 5, characterized in that, The second and third master rolls are for different products.

7. The OLED metal mask roll-to-roll production speed compensation method according to claim 1, characterized in that, When the etching pool lengths are inconsistent, the ramp-up linear velocity S needs to be recalculated. 1修 S 1修 = S1*L2 / L1; Where L1 is the etching pool length of the previous batch of master rolls, and L2 is the etching pool length of the current production equipment.

8. The OLED metal mask roll-to-roll production speed compensation method according to claim 7, characterized in that, An ion sensor is installed in the etching pool to stabilize the concentration of the etching solution.

9. The OLED metal mask roll-to-roll production speed compensation method according to claim 1, characterized in that, Test patterns for calculating etching rates are set on both sides of the master roll.

10. The OLED metal mask roll-to-roll production speed compensation method according to claim 9, characterized in that, Etching rate A = D / T; Where D is the thinning amount of the master roll, and T is the ratio of the etching groove length to the transmission linear speed.