Curved Nozzle Array for Uniform Organic Material Mixing in OLED Deposition
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Solution Overview
Problem
In organic light emitting diode (OLED) displays, the uniformity of organic material mixtures is compromised due to the use of multiple vapor deposition sources at different locations, leading to deteriorated characteristics of the OLED display.
Innovation Solution
A thin film forming apparatus with multiple vapor deposition sources and nozzles arranged on the same vapor deposition line, where the nozzles are inclined to ensure uniform mixing of organic materials, improving the uniformity of the mixture deposited on the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple vapor deposition sources are used to form organic emission layer, then the organic material can be vapor-deposited, but the mixture uniformity of organic material deteriorates
Solution Approach 1:
The patent applies dimensionality change by arranging nozzle holes on a curved surface (cylinder or cone) instead of a flat plane. This spatial reconfiguration allows vapor deposition sources to be positioned at different locations while their spray directions converge on the same deposition line, maintaining mixture uniformity through three-dimensional geometric arrangement rather than two-dimensional planar alignment.
Solution Approach 2:
The patent employs asymmetry by configuring nozzle holes with different orientations and angles on the curved surface. The nozzles are arranged to spray in different directions that converge at specific points on the deposition line, creating an asymmetric spray pattern that ensures uniform mixing despite the multiple source locations. This asymmetric arrangement compensates for the positional differences of multiple vapor deposition sources.
2Productivity
If multiple vapor deposition sources are positioned at different locations, then vapor deposition can proceed, but vapor deposition flux creates non-uniform mixture
Solution Approach 1:
The curved surface arrangement of nozzle holes in three-dimensional space enables multiple vapor deposition sources to operate simultaneously at different locations while directing their flux along a common curved deposition line. This spatial configuration maintains high deposition productivity while ensuring uniform mixture formation through geometric convergence of spray paths.
Solution Approach 2:
The patent applies local quality by configuring each nozzle hole with specific orientation and spray direction tailored to its position on the curved surface. Each vapor deposition source deposits material with locally optimized parameters (nozzle angle, orientation) that ensure uniform contribution to the overall mixture along the deposition line, allowing high productivity with uniformity.
3Manufacturing precision
If nozzles are arranged on same vapor deposition line, then mixture uniformity improves, but nozzle configuration becomes complex
Solution Approach 1:
The patent simplifies the complex nozzle configuration problem by transitioning from two-dimensional planar arrangement to three-dimensional curved surface arrangement. This dimensional change provides an intuitive geometric framework where nozzle positions, orientations, and spray directions can be systematically configured to achieve uniform mixture formation without complex calculations or adjustments.
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
The apparatus ensures uniform vapor deposition of organic materials, enhancing the characteristics of OLED displays by maintaining consistent thickness and improving deposition speed.
Implementation Method 1
the organic material is vapor-deposited by a vapor deposition source filled with an organic material
Implementation Method 2
the organic material heated in the vapor deposition source
Implementation Method 3
a thin film forming apparatus formed of a plurality of nozzles that spray (or vapor-deposit) the organic material
Data Source
AI summary
A thin film forming apparatus according to the embodiment includes a plurality of vapor deposition sources respectively separated from each other, a plurality of nozzle bodies connected to upper portions of the respective vapor deposition sources, and a plurality of nozzles connected to upper portions of the respective nozzle bodies. A nozzle hole of each of the nozzles is formed on a same vapor deposition line. Thus, according to the embodiment, the first organic material and the second organic material respectively sprayed through a first nozzle hole and a second nozzle hole can be uniformly mixed by disposing the first nozzle hole and the second nozzle on the same vapor deposition line.