Bubble Removal in Flexible Substrates via Thermal Gradient

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Solution Overview

Problem

Existing techniques fail to effectively remove bubbles formed due to volatilization in the polyimide layer of flexible OLED display panels after coating, leading to reduced manufacturing yield.

Innovation Solution

An apparatus and method involving a chamber with a heating plate and cooling conduit to control temperature gradients within the polyimide layer, using nitrogen gas to facilitate the removal of bubbles by evaporating volatile substances from the bottom portion faster than the top portion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If heating is applied to the polyimide layer to evaporate volatile substances, then bubble removal efficiency is improved, but the polyimide layer may be damaged due to excessive temperature

Engineering Contradiction:
Improvebubble removal efficiencyVSAvoidsubstrate damage
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies different temperatures to different regions of the polyimide layer. The bottom surface is heated to a higher temperature (first temperature) to promote evaporation of volatile substances, while the top surface is cooled to a lower temperature (second temperature) to prevent damage. This local quality differentiation allows effective bubble removal without substrate damage.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent changes the temperature parameter across the thickness of the polyimide layer. By maintaining a temperature gradient where the bottom surface is at a higher temperature and the top surface is at a lower temperature, the patent optimizes the evaporation process while protecting the substrate from thermal damage.

Inventive Principle:
Principle #35Parameter changes

2Use of energy by moving object

If uniform temperature is applied throughout the polyimide layer, then heating efficiency is improved, but temperature control precision is reduced due to heat loss

Engineering Contradiction:
Improveheating efficiencyVSAvoidtemperature control precision
Core Design Contradiction:
Use of energy by moving objectVSTemperature

Solution Approach 1:

The patent implements local quality by applying different temperatures to different regions. The bottom surface receives higher heating power to promote evaporation, while the top surface receives cooling to maintain precise temperature control and prevent excessive heat loss.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent utilizes thermal gradients to control the behavior of volatile substances. By creating a temperature difference between the bottom and top surfaces, the patent promotes upward movement of evaporated gases while maintaining overall temperature control precision.

Inventive Principle:
Principle #37Thermal expansion

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

Effectively removes bubbles from the polyimide layer by exploiting temperature differences, enhancing the yield of flexible electronic display products.

Implementation Method 1

heating a bottom portion of the flexible substrate using the heating plate, wherein the heating plate is controlled at a temperature ranging from 550° C. and 750° C.

Methodology Applied
Scientific EffectHeating: Heating

Implementation Method 2

cooling a top portion of the flexible substrate using the cooling conduit, wherein the cooling conduit is maintained at about room temperature

Methodology Applied
Scientific EffectCooling: Cooling

Implementation Method 3

By controlling temperatures of a bottom portion and a top portion of the PI layer, gases in the bottom portion of the PI layer evaporate faster than gases in the top portion of the PI layer

Methodology Applied
Scientific EffectConvection: Convection

Data Source

PatentUS11420228B2Apparatus and method for removing bubbles in flexible substrate
Publication Date: 2022.08.23 WUHAN CHINA STAR OPTOELECTRONICS SEMICONDUCTOR DISPLAY TECHNOLOGY CO LTD
  • US11420228B2 patent drawing

AI summary

The present disclosure provides an apparatus for removing bubbles in a flexible substrate. The flexible substrate includes a baseplate and a polyimide layer coated on the baseplate. The apparatus includes a chamber including a top wall, a sidewall, and a bottom wall, wherein the top wall, the sidewall, and the bottom wall define an accommodation space; a heating plate disposed in the accommodation space; and a cooling conduit embedded in at least one of the top wall and the sidewall of the chamber.