Float Bath Nanoparticle Coating for Continuous Light Extraction
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Solution Overview
Problem
OLEDs and photovoltaic devices suffer from low light extraction efficiency due to trapped light within the optical waveguide effect, and conventional coating processes are time and labor intensive, lacking a continuous process for applying multiple layers.
Innovation Solution
A float glass system with integrated nanoparticle and vapor deposition coaters in the float bath allows for the continuous embedding of nanoparticles and application of functional layers, enhancing light extraction and friction modification, and enabling a continuous coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional batch coating processes are used to apply coating layers to substrates, then each layer can be applied with controlled deposition, but the process becomes time intensive and labor intensive
Solution Approach 1:
The patent combines multiple separate coating stations into a single integrated float glass coating system where nanoparticle coaters, CVD coaters, and friction modification coaters are merged into one continuous processing line, allowing multiple coating layers to be applied simultaneously in a single pass rather than requiring sequential batch processing at separate stations
Solution Approach 2:
The float glass coating system enables continuous coating of substrates as they pass through the float bath, replacing the discontinuous batch coating process where substrates must be manually transferred between separate coating stations. The continuous action maintains coating quality while dramatically increasing throughput and reducing labor requirements
2Reliability
If nanoparticles are embedded into the substrate to enhance light extraction, then light extraction efficiency increases, but the substrate must be processed at controlled viscosity conditions
Solution Approach 1:
The system utilizes controlled changes in substrate viscosity within the float bath to enable nanoparticle embedding at specific locations. By adjusting temperature and viscosity parameters along the float path, nanoparticles are embedded only in regions where the substrate viscosity is appropriate, while other regions maintain their original properties for subsequent coating steps
Solution Approach 2:
Nanoparticles are embedded into the substrate beforehand during the float glass manufacturing process, before subsequent coating layers are applied. This preliminary embedding ensures that the light extraction enhancement is already in place before the substrate enters the coating line, simplifying the overall process control
3Adaptability or versatility
If multiple nanoparticle coaters are used to apply different nanoparticles on glass surfaces, then functional properties are enhanced, but the system complexity increases
Solution Approach 1:
The float glass coating system is designed as a universal platform that can accommodate multiple types of nanoparticle coaters (flame spray, CVD, particle deposition) within a single integrated line. This multi-functional system can apply different nanoparticles for different functions (light extraction, friction modification, conductivity) without requiring separate processing lines for each function
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 increases light extraction efficiency by embedding nanoparticles for scattering and enhancing electromagnetic radiation output, while transitioning from a batch to a continuous coating process, reducing time and labor requirements.
Implementation Method 1
embedding of nanoparticles in a substrate... The nanoparticles can be used for light extraction enhancement in OLED devices
Implementation Method 2
embedding of nanoparticles in a substrate at a viscosity of the substrate
Implementation Method 3
vapor deposition coaters located in the float bath
Data Source
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AI summary
A float bath coating system includes at least one nanoparticle coater located in a float bath. The at least one nanoparticle coater includes a housing, a nanoparticle discharge slot, a first combustion slot, and a second combustion slot. The nanoparticle discharge slot is connected to a nanoparticle source and a carrier fluid source. The first combustion slot is connected to a fuel source and an oxidizer source. The second combustion slot is connected to a fuel source and an oxidizer source.