OLED Roller Coating Apparatus for RGB Sub-pixel Formation
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Solution Overview
Problem
The existing methods for manufacturing OLED panels using the evaporation technique are complex, involve high investment in equipment, and result in low production yield and efficiency due to difficulties in controlling the quality of screen printing plates and the cleaning process, leading to a long production cycle and inefficient utilization of organic light-emitting coatings.
Innovation Solution
A manufacturing method and apparatus that uses a roller with RGB liquid outlets to spray organic light-emitting coating onto a substrate, forming RGB trichromatic sub-pixels in a single step, with an alignment device and flow control system to ensure precise placement and size adjustment, simplifying the process and improving coating utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the evaporation technique is used to form sub-pixels on OLED panel, then the sub-pixels can be formed with existing technology, but the production process becomes complicated and requires multiple corollary equipment including screen printing plate manufacturing equipment and specialized cleaning machines
Solution Approach 1:
The patent combines multiple separate processes (screen printing plate manufacturing, coating application, and cleaning) into a single integrated roller-based coating device. The roller directly applies organic light-emitting coating material to the substrate without requiring separate screen printing plates or cleaning equipment, thereby simplifying the production line while maintaining sub-pixel formation quality.
Solution Approach 2:
The patent extracts and eliminates the screen printing plate component from the traditional evaporation technique process. By using a roller that directly holds and applies coating material, the system removes the intermediate screen printing plate step, reducing equipment requirements and process complexity while maintaining the ability to form precise sub-pixel patterns.
2Manufacturing precision
If the evaporation technique with screen printing plates is used, then sub-pixels can be formed, but the quality of screen printing plates is difficult to control resulting in low production yield
Solution Approach 1:
The roller-based coating device is self-contained and directly applies coating material without requiring external screen printing plates. The roller itself serves as both the application tool and the pattern-defining element, eliminating quality control issues associated with separate screen printing plates while maintaining precise sub-pixel formation capability.
3Manufacturing precision
If the evaporation technique is used to form sub-pixels, then the panel can be manufactured, but the cleaning process becomes complicated requiring specialized cleaning machines
Solution Approach 1:
The patent extracts and eliminates the need for specialized cleaning equipment by using a roller-based system that inherently avoids the contamination issues of screen printing. The direct coating method does not require the complex cleaning processes needed to remove screen printing residue, thereby simplifying the production line while maintaining sub-pixel formation accuracy.
4Manufacturing precision
If the evaporation technique with multiple processes is used, then sub-pixels can be formed, but the production cycle becomes long and production efficiency is low
Solution Approach 1:
The patent merges multiple sequential processes (screen printing plate manufacturing, coating application, and cleaning) into a single integrated roller coating operation. This consolidation reduces the total number of process steps and eliminates the need for intermediate handling and equipment transitions, thereby maintaining sub-pixel formation quality while significantly improving production efficiency.
Solution Approach 2:
The roller-based coating device enables continuous coating application as the substrate moves through the system, eliminating the stop-start nature of traditional screen printing processes. The roller continuously deposits coating material onto the substrate surface, maintaining production flow and improving overall productivity while preserving sub-pixel formation 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
This approach simplifies the production process, increases efficiency, and enhances the utilization of organic light-emitting coatings by forming sub-pixels in a single step, thereby improving the production efficiency of OLED panels.
Implementation Method 1
providing a roller with a plurality of RGB liquid outlets, the RGB liquid outlets capable of spraying RGB organic light-emitting coating liquid
Data Source
AI summary
The present disclosure provides a manufacturing method for an OLED panel and an OLED panel manufacturing apparatus. The OLED panel manufacturing apparatus include at least one roller; at least one outlet used to print a plurality of RGB trichromatic sub-pixels disposed in sequence on a substrate by spraying organic light-emitting coating; and at least one pipe used to convey the organic light-emitting coating. By simultaneously printing the RGB trichromatic sub-pixels on the substrate in a letterpress printing way, the present disclosure can maximize the utilization of the organic light-emitting coating forming sub-pixels, simplify the production process and cycle, and increase the production efficiency.