Movable Multi-Material Deposition for Flexible Display Layers
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Solution Overview
Problem
Existing manufacturing processes for display devices are inefficient, leading to high costs and material wastage due to the complexity of layer deposition on flexible substrates.
Innovation Solution
A manufacturing apparatus and method that utilizes a chamber with a deposition source and a moving part to sequentially deposit layers of deposition materials on a display substrate, defining specific areas for each material to optimize layer composition and reduce material wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional deposition process is used to deposit multiple layers on display substrate, then the display device can be manufactured, but the manufacturing time and costs increase and material piling up phenomenon occurs
Solution Approach 1:
The deposition source is made movable along the traveling direction of the display substrate. By dynamically adjusting the position of the deposition source relative to the substrate, different deposition areas (first, second, and third areas) can be selectively targeted. This dynamic positioning enables continuous deposition processes without requiring multiple separate deposition steps, thereby reducing manufacturing time while maintaining layer deposition quality.
Solution Approach 2:
The single deposition source is designed to eject multiple different deposition materials (first deposition material and second deposition material) through different deposition parts. This multi-functional deposition source can deposit different materials in different areas of the substrate during a single pass, eliminating the need for multiple deposition sources or repeated deposition cycles, thus improving productivity without sacrificing manufacturing precision.
2Manufacturing precision
If a conventional deposition process is used to deposit multiple layers on display substrate, then the display device can be manufactured, but material piling up phenomenon occurs
Solution Approach 1:
The deposition process is divided into different deposition areas (first, second, and third areas) along the substrate traveling direction, with each area receiving specific deposition materials at controlled rates. The first deposition material is deposited in the first and second areas, while the second deposition material is deposited in the second and third areas. This localized control of material deposition prevents excessive material accumulation (piling up) in any single area while ensuring each region receives the appropriate material composition for optimal layer quality.
Solution Approach 2:
By dynamically positioning the deposition source and controlling which deposition parts are active at different positions along the substrate, the system optimizes material utilization. Materials are deposited only where needed during each pass, reducing waste from overspray or unnecessary deposition in areas where material is not required, thereby reducing material loss while maintaining deposition 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 reduces manufacturing time and costs while improving the efficiency of layer deposition on flexible substrates, enhancing the manufacturing process for display devices.
Implementation Method 1
a deposition source arranged in the chamber and including a first deposition part that ejects a first deposition material towards the display substrate, and a second deposition part that ejects a second deposition material towards the display substrate
Data Source
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AI summary
An apparatus for manufacturing a display device which deposits on a display substrate arranged in a virtual plane a first deposition material and a second deposition material. The apparatus may include a deposition source with multiple deposition parts that include differing deposition materials onto different areas or portions of the virtual plane. The deposition source moves with respect to the display substrate so that the deposition materials may be deposited onto the display substrate in case that at least one of the different areas of the virtual plane coincide with a location of the display substate.