Enclosed Coating System for Patterned OLED Fabrication
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Solution Overview
Problem
Scaling high-volume manufacturing of RGB OLED displays and other electronic devices across various substrate formats is challenging due to material susceptibility to oxidation and chemical degradation, requiring an environmentally controlled, inert, and low-particle coating system that can maintain low levels of reactive species and particles.
Innovation Solution
An enclosed coating system with a gas circulation and filtration system, thermal regulation, and particle control, allowing for patterned area coating using slot die coating, which maintains an inert gas environment with low particulate levels and provides ready access for maintenance, reducing material waste and processing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional spray equipment is used to apply coating materials, then coating application is achieved, but hazardous volatile organic compounds (VOCs) are released into the atmosphere causing environmental pollution
Solution Approach 1:
The patent changes the physical state parameter of the coating material from liquid to aerosol form. This transformation allows the coating to be applied without traditional solvents that evaporate as VOCs, thereby reducing harmful emissions while maintaining coating application efficiency through controlled aerosol deposition
Solution Approach 2:
The patent creates a controlled environment by enclosing the coating application area and using water-based or solvent-free aerosol formulations. This inert approach prevents the release of hazardous VOCs into the atmosphere while still achieving effective coating coverage on target surfaces
2Loss of substance
If conventional spray equipment is used to apply coating materials, then coating application is achieved, but coating material is wasted due to overspray and improper application
Solution Approach 1:
The patent incorporates sensors that detect the presence and characteristics of the target surface, providing feedback to the control system. This feedback mechanism allows the system to adjust aerosol generation parameters in real-time, optimizing coating material deposition and minimizing waste from overspray or improper application
Solution Approach 2:
The patent employs dynamically adjustable aerosol generation parameters including particle size distribution, generation rate, and deposition timing. These dynamic adjustments allow the system to adapt to different coating requirements and surface conditions, improving material utilization efficiency while maintaining ease of operation through automated control
3Manufacturing precision
If multiple coats are applied to achieve uniform coverage and hide imperfections, then coating quality is improved, but application time and labor costs increase
Solution Approach 1:
The patent prepares the coating material in advance as a pre-formed aerosol with optimized particle size distribution and composition. This preliminary preparation allows the coating to be applied in fewer passes with better uniformity, reducing the number of required coats and overall application time while maintaining high manufacturing precision
Solution Approach 2:
The patent modifies the aerosol particle size parameters to optimize deposition characteristics. By controlling particle size distribution within specific ranges, the system achieves more uniform coating coverage in fewer applications, thereby improving manufacturing precision while reducing the time required for multiple coating passes
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 system effectively coats organic film layers on diverse electronic devices with high yield and longevity, maintaining low reactive species levels and particle deposition rates, enhancing the stability and longevity of OLED materials and reducing manufacturing downtime.
Implementation Method 1
an aerosol generation system that transforms the liquid coating material into fine aerosol particles
Implementation Method 2
The system utilizes controlled evaporation of the aerosol carrier to deposit coating material onto the substrate surface
Data Source
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AI summary
Embodiments of an enclosed coating system according to the present teachings can be useful for patterned area coating of substrates in the manufacture of a variety of apparatuses and devices in a wide range of technology areas, for example, but not limited by, OLED displays, OLED lighting, organic photovoltaics, Perovskite solar cells, and organic semiconductor circuits. Enclosed and environmentally controlled coating systems of the present teachings can provide several advantages, such as: 1) Elimination of a range of vacuum processing operations such coating-based fabrication can be performed at atmospheric pressure. 2) Controlled patterned coating eliminates material waste, as well as eliminating additional processing typically required to achieve patterning of an organic layer. 3) Various formulations used for patterned coating with various embodiments of an enclosed coating apparatus of the present teachings can have a wide range of physical properties, such as viscosity and surface tension.