Donor Film Frame Assembly for OLED Lamination
Solution Overview
Problem
Conventional methods for manufacturing organic light emitting displays using donor films often result in defects due to uneven lamination caused by wrinkling of the donor film during thermal processing, leading to issues like wrinkles and stains in the transferred organic thin film.
Innovation Solution
A frame assembly for the donor film, comprising a main frame, an extension frame, and a clamping unit, which allows for additional stretching of the donor film to maintain a tensile state, preventing drooping and wrinkling, and ensuring even lamination on the acceptor substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heat is applied to the donor film during thermal processing, then the organic material is transferred to the acceptor substrate, but the donor film droops or becomes wrinkled causing uneven lamination
Solution Approach 1:
The donor film is pre-stretched in a first direction before thermal processing using a frame assembly. This preliminary stretching creates tension that counteracts the drooping and wrinkling that occurs during subsequent heat treatment, allowing the film to maintain its flatness throughout the manufacturing process.
Solution Approach 2:
The frame assembly is designed to be extendable in a second direction (perpendicular to the first stretching direction) during or after thermal processing. This dynamic adjustment allows additional stretching to compensate for any film relaxation or deformation that occurs during heating, ensuring the film remains flat and evenly laminated on the acceptor substrate.
2Stability of the object's composition
If the donor film is stretched in one direction only, then the film tension is maintained, but the film still wrinkles when heat is applied from all directions
Solution Approach 1:
The frame assembly transitions from a static single-direction stretch to a dynamic multi-directional stretch system. The frame can be extended not only in the first direction (initial stretching) but also in the second perpendicular direction (additional stretching during/after heating), adapting to the thermal processing conditions and maintaining film stability throughout the process.
Solution Approach 2:
The solution adds a second dimension of stretching perpendicular to the first stretching direction. This multi-directional stretching approach creates a more uniform tensile state across the donor film, preventing wrinkles and drooping that occur when heat is applied from all directions during thermal processing.
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 frame assembly ensures even lamination of the donor film on the acceptor substrate, reducing defects such as wrinkles and stains in the organic thin film, thereby improving the quality of the organic light emitting display.
Implementation Method 1
a light-to-heat conversion (LTHC) layer... Light emitted from the light source is absorbed by the LTHC layer on the donor film and converted into thermal energy
Implementation Method 2
a main frame, an extension frame, and a clamping unit... configured to selectively stretch the donor film... additional stretching of the donor film using the frame assembly
Data Source
AI summary
A frame assembly for a donor film includes a main frame, an extension frame, and a clamping unit. The main frame extends in a first direction. The extension frame includes a cavity region configured to receive at least a portion of the main frame, the extension frame being coupled to at least one side of the main frame and moveable in the first direction relative to the main frame. The clamping unit is configured to detachably couple the donor film to the frame assembly, the extension frame being disposed between the at least one side of the main frame and the clamping unit.