Roll-Form OLED Substrate with Gap Protrusions for Defect Prevention
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Solution Overview
Problem
The existing manufacturing process of organic light-emitting elements faces quality deterioration due to direct contact between the substrate and deposition surface during repetitive winding and unwinding, leading to defects in the deposition layer.
Innovation Solution
The solution involves forming gap maintaining protrusions on the substrate surface by printing insulating or conductive transparent/color ink, which protrude above the deposition layer to prevent direct contact and protect the deposition material during the rolling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a roll process is used to improve production speed and reduce equipment size, then productivity increases and manufacturing cost decreases, but the substrate and deposition surface come into contact during winding and unwinding, causing defects in the deposition layer
Solution Approach 1:
A release film is introduced as an intermediary layer between the substrate and the deposition surface. This release film prevents direct contact between the substrate and deposition surface during the roll process, thereby avoiding defects in the deposition layer while maintaining the productivity benefits of the roll process.
Solution Approach 2:
The release film is applied to the substrate before the deposition process begins. This preliminary action ensures that the substrate is protected from contact with the deposition surface throughout the entire winding and unwinding process, preventing defects before they can occur.
2Manufacturing precision
If a large-sized flat glass substrate is used to increase equipment size and clean room size, then manufacturing precision may improve, but manufacturing cost increases
Solution Approach 1:
The release film serves as a disposable protective layer that is applied to the substrate and then removed or left in place after serving its protective function. This inexpensive protective measure prevents costly defects in the deposition layer without requiring expensive large-sized equipment or clean rooms.
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 approach effectively prevents defects in the deposition layer by creating a gap between the substrate and deposition surface, enhancing the quality and reliability of the organic light-emitting elements during the manufacturing process.
Implementation Method 1
printing insulating or conductive transparent/color ink according to the type and characteristics of the organic light emitting element on the substrate to form a plurality of protrusions
Implementation Method 2
the vacuum deposition method has been widely used in consideration of the advantages of increase in the purity of constituent layer forming materials and production of long-life organic light-emitting elements
Data Source
AI summary
Provided are a light-emitting element for lighting that is manufactured while being supplied in a roll form, including: a substrate that is wound/unwound on a roll, on which a deposition material is to be deposited with a pattern; gap maintaining protrusions that protrude at a plurality of positions on one surface of the substrate, and are configured to protect the deposition material while contacting the other surface of the substrate when the substrate is wound and unwound on the roll; an insulating layer that is disposed on the one surface of the substrate and is formed by stacking an insulating material; and at least one deposition layer that is formed by depositing at least one deposition material on the one surface of the insulating layer, in which the gap maintaining protrusions have a protrusion height greater than a height of the deposition layer, and a method for manufacturing the same.