Gas enclosure assembly and system
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Solution Overview
Problem
The challenge lies in scaling OLED printing systems to larger formats while maintaining an inert, particle-free environment, which is essential for producing high-quality OLED displays, as existing solutions struggle to effectively manage reactive species and particle contamination, especially when dealing with larger substrates like Gen 7.5 and Gen 8.5 sizes.
Innovation Solution
A hermetically-sealed gas enclosure assembly and system that integrates gas circulation, filtration, and purification components, allowing for the minimization of inert gas volume, optimized access for maintenance, and the maintenance of low reactive species levels, using a pressurized inert gas recirculation system to ensure a stable internal pressure and efficient removal of particles and gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a large facility is hermetically sealed to maintain inert atmosphere for large-format OLED printing, then the protective environment is improved, but the complexity of sealing and maintaining the enclosure increases significantly
Solution Approach 1:
The gas enclosure is divided into multiple modular sections that can be assembled together. Each section has standardized sealing interfaces, which reduces the overall sealing complexity compared to a single large sealed structure. The modular design allows for easier assembly, disassembly, and maintenance while maintaining the hermetic seal required for inert atmosphere.
2Ease of operation
If cabling, wiring and tubing are fed into the gas enclosure to operate the printing system, then the system functionality is improved, but the dead volume for reactive species increases
Solution Approach 1:
Glove ports with attached gloves serve as intermediaries between the operator and the enclosed printing system. This allows operators to manipulate substrates and equipment inside the inert atmosphere without requiring extensive cabling, wiring, or tubing penetrations. The gloves provide a flexible interface that minimizes dead volume while maintaining full system functionality.
Solution Approach 2:
The printing system utilizes pneumatic components and fluid delivery through the glove port interface rather than extensive hard-wired connections. This reduces the amount of tubing and wiring penetrating the enclosure, thereby minimizing dead volume where reactive species could be occluded while still enabling full operation of the printing system.
3Ease of operation
If the gas enclosure is designed for easy access during processing, then the operational accessibility is improved, but the hermetic sealing integrity may be compromised
Solution Approach 1:
The enclosure is segmented into modular sections with standardized interfaces. Access during processing is achieved by opening individual sections or panels while maintaining seals on remaining sections. This allows operational access without compromising the hermetic integrity of the entire enclosure, as each module maintains its own seal independence.
Solution Approach 2:
Glove ports with flexible gloves provide access during processing without requiring rigid openings that would compromise sealing. The flexible membrane maintains the hermetic seal while allowing operators to reach inside and manipulate equipment and substrates during processing operations.
4Object-affected harmful factors
If gas purification systems are continuously operated to remove reactive species, then the inert atmosphere quality is improved, but the energy consumption and operational complexity increase
Solution Approach 1:
Gas purification operates periodically rather than continuously. The system monitors reactive species levels and activates purification only when thresholds are exceeded or during scheduled maintenance cycles. This periodic operation maintains the required inert atmosphere quality while significantly reducing energy consumption compared to continuous operation.
Solution Approach 2:
The gas enclosure system includes self-monitoring capabilities that detect when purification is needed based on internal conditions. The system automatically manages its own atmosphere quality without requiring constant external intervention or continuous high-energy operation, optimizing the balance between atmosphere quality and energy consumption.
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
This solution enables the production of OLED panels on larger substrates by maintaining low levels of reactive species and particles, meeting stringent clean room standards and minimizing downtime for maintenance, thus overcoming the limitations of existing technologies in scaling OLED printing.
Implementation Method 1
using a pressurized inert gas recirculation system to ensure a stable internal pressure
Implementation Method 2
integrates gas circulation, filtration, and purification components
Implementation Method 3
integrates gas circulation, filtration, and purification components
Data Source
AI summary
The present teachings relate to various embodiments of an hermetically-sealed gas enclosure assembly and system that can be readily transportable and assemblable and provide for maintaining a minimum inert gas volume and maximal access to various devices and apparatuses enclosed therein. Various embodiments of an hermetically-sealed gas enclosure assembly and system of the present teachings can have a gas enclosure assembly constructed in a fashion that minimizes the internal volume of a gas enclosure assembly, and at the same time optimizes the working space to accommodate a variety of footprints of various OLED printing systems. Various embodiments of a gas enclosure assembly so constructed additionally provide ready access to the interior of a gas enclosure assembly from the exterior during processing and readily access to the interior for maintenance, while minimizing downtime.