High-Flatness Metal Foil Processing for Low Residual Stress
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Solution Overview
Problem
The existing methods for preparing fine metal masks face challenges due to impurities and contaminants generated during the manufacturing process of high-flatness metal foils, resulting in low yield and poor flatness, which are not suitable for producing high-quality OLED light emitting devices.
Innovation Solution
A method involving precision rolling, heat treatment, and tension leveling of metal foils made from alloys like Invar, iron-nickel, and iron-cobalt-chromium, with specific composition ranges and atmospheric conditions, to achieve high-flatness and low residual stress, ensuring improved cleanliness and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-stage conventional hot rolling, heat treatment, and cold rolling are used to prepare ultra-thin metal sheets, then the required thickness is achieved, but impurities and contaminants are generated resulting in low yield and poor flatness
Solution Approach 1:
The patent extracts and removes harmful impurities and contaminants from the metal foil during the manufacturing process through cleaning treatments between rolling stages, preventing their accumulation and negative effects on flatness and yield
Solution Approach 2:
The patent applies preliminary cleaning actions between rolling and heat treatment stages to prevent impurity accumulation before it affects the final flatness, addressing the problem proactively rather than reactively
2Manufacturing precision
If multiple rolling and heat treatment processes are used to achieve thin metal foil, then the thickness requirement is met, but the manufacturing procedure becomes long and costly with low yield
Solution Approach 1:
The patent implements continuous rolling processes with integrated heat treatment and cleaning stages, eliminating idle time between operations and maintaining continuous material flow to reduce overall manufacturing cycle time while preserving thickness precision
Solution Approach 2:
The patent combines multiple rolling and heat treatment operations into an integrated continuous process, merging previously separate stages into a unified manufacturing flow that reduces total process time while maintaining quality standards
3Productivity
If conventional rolling methods are used to manufacture thin metal foil, then the foil is produced, but the flatness and residual stress are not ideal resulting in yield loss
Solution Approach 1:
The patent systematically changes process parameters including rolling reduction ratios, heat treatment temperatures and durations, and tension leveling forces to optimize both flatness and yield, moving from conventional fixed parameters to optimized variable parameters
Solution Approach 2:
The patent implements feedback control where flatness and residual stress measurements from previous stages inform adjustments in subsequent rolling and heat treatment parameters, creating a closed-loop system that continuously optimizes yield and quality
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 method produces metal foils with high flatness and low residual stress, enhancing the quality and reliability of fine metal masks and subsequent AMOLED fabrication, with increased yield and reduced production time and costs.
Implementation Method 1
S103, final heat treatment: performing, by a heat treatment device, heat treatment at least once on the metal foil experiencing the precision rolling according to a preset temperature and a preset time
Implementation Method 2
S104, tension leveling: performing tension leveling at least once on the metal foil experiencing the rolling and the heat treatment using a tension leveler
Data Source
AI summary
Disclosed is a method for preparing a high-flatness metal foil suitable for making a metal mask, and the method comprises the following steps: forming a raw metal coarse foil; rolling the raw metal coarse foil at least once into a high-flatness metal foil; performing, by a heat treatment device, heat treatment processing on the precisely rolled metal foil according to a preset temperature and a preset time; using a tension leveler to perform tension leveling on the rolled and heat-treated metal foil; and obtaining a high-flatness metal foil after completion of the tension leveling and forming a rolled metal foil in a continuous forming process. The resulting metal foil has high flatness and low residual stress, which improves quality and performance of the metal foil and is suitable for the fabrication of fine metal masks.