OLED Roll Deposition Tension Control for Stable Layer Formation
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Solution Overview
Problem
The existing roll process for manufacturing OLEDs faces challenges in maintaining sufficient tension on the base to prevent warpage and vibration, which can lead to contamination, uneven layer thickness, and damage to the substrate, particularly when using flexible or thin glass substrates.
Innovation Solution
The use of a band-shaped base with holes at predetermined intervals and rotating rolling members with protrusions that move the base transversely, allowing for precise tension application and minimizing contamination through a shield member with magnetic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the base passes above the deposition sources over a long area to form multiple layers, then all constituent layers can be deposited sequentially, but the base becomes vulnerable to warpage and vibration due to insufficient tension
Solution Approach 1:
A tension application mechanism is introduced as an intermediary component between the base and the deposition sources. This mechanism applies sufficient tension to the base during its passage, preventing warpage and vibration while maintaining the ability to control layer thickness through the deposition process
Solution Approach 2:
The system transitions from a static base handling approach to a dynamic one where tension is actively applied and adjusted during the base's movement through the deposition sources. This dynamic tension application ensures the base remains stable throughout the entire deposition process
2Reliability
If the amount of tension is increased to provide sufficient tension to the base, then warpage and vibration are prevented, but a stretching force acts on the base causing deformation
Solution Approach 1:
The tension application mechanism allows for precise control and adjustment of tension parameters. By optimizing the tension level, the system achieves sufficient base stability without excessive stretching forces that would cause deformation. The tension is controlled within a specific range that balances stability and shape preservation
3Reliability
If excessive tension is applied to thin glass substrate, then sufficient tension is provided to prevent warpage, but the substrate may be damaged
Solution Approach 1:
The system implements parameter control that adapts to different substrate types and thicknesses. For thin glass substrates, the tension application is optimized to provide sufficient stability while remaining below the damage threshold. This involves controlling tension within safe limits specific to the substrate's mechanical properties
4Object-affected harmful factors
If the deposition sources are arranged under the base to suppress foreign material introduction, then contamination is reduced, but the base needs to pass above all deposition sources over a long area
Solution Approach 1:
The tension application mechanism serves as an intermediary that enables the base to span the long distance between deposition sources without warping or vibrating. This resolves the contradiction by providing the structural support needed to maintain the contamination-free configuration
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 ensures consistent tension to prevent base warpage and vibration, reduces contamination, and maintains desired light emission properties by ensuring accurate deposition of layers on the OLED substrate.
Implementation Method 1
A plurality of rolling members 5, configured to move, in a transverse direction, a band-shaped base 3 having holes 31a and 31b formed at predetermined intervals
Implementation Method 2
a deposition unit configured to discharge a vaporization material from a deposition source and sequentially depositing the discharged vaporization material on one surface of the base
Implementation Method 3
discharging a vaporization material from a deposition source and sequentially depositing the discharged vaporization material on one surface of the base
Data Source
AI summary
An apparatus and method for manufacturing an organic light emitting diode (OLED) for lighting are disclosed. The manufacturing apparatus includes a plurality of rolling members configured to move, in a transverse direction, a band-shaped base having holes formed at predetermined intervals at both width-direction ends thereof, and arranged at predetermined intervals along a movement direction of the base, and a deposition unit configured to discharge a vaporization material from a deposition source and sequentially depositing the discharged vaporization material on one surface of the base, along with the movement of the base. A plurality of protrusion members are formed on one surface of each of the rolling members, to move the base by being inserted in and released from the holes at both ends of the base along with rotation of the tolling members.