Nanoparticle Coating Head for Continuous Light-Extraction Layers
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Solution Overview
Problem
OLEDs and photovoltaic devices suffer from low light emission efficiency due to trapped light within the device, and current coating processes are batch-intensive, which is time and labor-consuming.
Innovation Solution
A nanoparticle coater system for continuous coating processes that applies nanoparticles and volatile precursors to glass substrates, enhancing light extraction and modifying friction coefficients, using combustion slots and vapor deposition to form multiple layers and regions.
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 due to transferring substrates between separate coating stations
Solution Approach 1:
The patent combines multiple coating stations into a single integrated apparatus where substrates remain stationary while multiple coating heads apply different layers sequentially. This merging eliminates the need to transfer substrates between separate stations, maintaining coating precision while dramatically improving productivity by enabling continuous multi-layer deposition in one location.
Solution Approach 2:
The invention transitions from a linear sequential process (one coating station after another requiring substrate transfer) to a parallel multi-dimensional approach where multiple coating heads operate simultaneously around a stationary substrate. This dimensional reorganization allows multiple layers to be deposited concurrently, resolving the contradiction between controlled deposition and process efficiency.
2Use of energy by moving object
If light is emitted from the organic material in OLED devices, then the organic compounds can convert electrical energy to light, but a large percentage of light is trapped inside the device due to the optical waveguide effect at various interfaces
Solution Approach 1:
The patent applies local quality modifications at the substrate surfaces through friction-based treatments that create specific surface characteristics in targeted areas. These localized surface modifications alter the optical properties at critical interfaces, reducing the waveguide effect and enabling trapped light to escape selectively from treated regions without affecting the overall device structure or electrical-to-light conversion process.
Solution Approach 2:
The invention changes the surface parameters (friction coefficient, surface roughness) of the substrate through controlled friction processes. These parameter changes modify the optical interface properties, reducing total internal reflection and enabling improved light extraction efficiency while maintaining the core OLED functionality of converting electrical energy to light emission.
3Ease of manufacture
If photovoltaic devices use thin film PV cells with conventional coating methods, then the device structure can be manufactured, but the efficiency of converting incident light to electric energy remains relatively low with only up to 20% conversion at the module level
Solution Approach 1:
The patent modifies surface parameters through friction-based treatments to enhance light trapping and absorption in thin film PV cells. By changing surface roughness and friction characteristics, the device achieves improved optical coupling and extended light paths within the active layer, thereby increasing the fraction of incident light converted to electric energy while maintaining ease of manufacture through continuous processing.
Solution Approach 2:
The invention applies localized surface treatments to specific regions of the PV cell substrate to optimize light absorption in those areas. These local quality modifications create enhanced optical interaction zones that increase the overall conversion efficiency without requiring complete restructuring of the entire device, thus maintaining manufacturing simplicity while improving energy conversion productivity.
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
Enhances light extraction and reduces friction, improving the efficiency of OLEDs and photovoltaic devices while transitioning to a more efficient, continuous coating process.
Implementation Method 1
a first combustion slot and a second combustion slot. The nanoparticle coater can include a carrier fluid source in communication with the nanoparticle discharge slot. The nanoparticle coater can include a fuel source in communication with the first combustion slot and an oxidizer source in communication with the first combustion slot. The fuel source can be ignited at the first combustion slot to form a first flame. The oxidizer source can be ignited at the second combustion slot to form a second flame.
Implementation Method 2
A nanoparticle coater system for continuous coating processes that applies nanoparticles and volatile precursors to glass substrates, enhancing light extraction and modifying friction coefficients, using combustion slots and vapor deposition to form multiple layers and regions.
Data Source
AI summary
A nanoparticle coater includes a housing; a nanoparticle discharge slot; a first combustion slot; and a second combustion slot.