Coating Apparatus for Uniform Organic Layer Formation
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Solution Overview
Problem
Conventional methods for forming uniform layers in flat panel display devices, such as LCD and OLED, face challenges in achieving consistent thickness and preventing deformation due to separate coating and drying processes, which can result in non-uniform layers and thermal deformations.
Innovation Solution
A coating apparatus with a stage, a coating part for applying material, and a heating source that supplies uniform heat to the entire coating target, allowing for simultaneous coating and drying of organic layers at temperatures between 100° C to 200° C, preventing material flow and thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate coating and drying processes are used, then the coating material can be applied and dried, but the layer thickness becomes non-uniform and thermal deformation occurs
Solution Approach 1:
The patent combines the coating process and drying process into a single integrated apparatus. The coating head applies coating material while the heating source simultaneously dries it, eliminating the need for separate coating and drying equipment. This merging of processes resolves the technical contradiction by achieving uniform layer thickness without thermal deformation while maintaining process efficiency.
Solution Approach 2:
The heating source is positioned to pre-heat the substrate before coating material application, and continues heating during the coating process. This preliminary and continuous heating action prevents thermal shock and deformation that would occur with post-coating drying, thereby achieving uniform layer thickness while avoiding the complexity of separate processing steps.
2Reliability
If heating is applied after coating to dry the material, then the coating material dries, but thermal deformation and material flow occur
Solution Approach 1:
The heating source operates continuously during the coating process rather than being applied after coating completion. This continuous heating action dries the coating material as it is being applied, preventing material flow and thermal deformation while reducing the total processing time. The useful action of heating continues without interruption throughout the coating operation.
3Manufacturing precision
If uniform heat is supplied to the entire coating target, then drying is achieved, but thermal deformation may occur if not controlled
Solution Approach 1:
The patent employs controlled temperature parameters in the heating source, maintaining heating temperature within a specific range that is sufficient to dry the coating material but low enough to prevent thermal deformation. The heating temperature parameter is optimized to achieve uniform drying while preserving layer integrity, resolving the contradiction between achieving layer uniformity and controlling heating temperature.
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
Ensures the formation of layers with substantially uniform thickness and characteristics, preventing deformation and thermal issues associated with conventional separate coating and drying processes, while maintaining precision and quality.
Implementation Method 1
a heating source opposite to and spaced from the stage, and supplying heat to the coating target after applying the coating material onto the coating target
Implementation Method 2
The liquid coating material may be dried to finalize a layer
Data Source
AI summary
A coating apparatus includes a stage supporting a coating target, a coating part on the stage, the coating part being configured to apply a coating material onto the coating target, and a heating source opposite to and spaced apart from the stage, the heating source being configured to supply heat to the coating target after application of the coating material onto the coating target.