Reel-to-Reel Drying Chamber with IR and Hot Air Uniformity
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Solution Overview
Problem
Existing reel-to-reel drying apparatuses face challenges in achieving uniform heat transfer and maintaining substrate height, leading to temperature distribution variations and local drying issues, which can cause contamination and quality degradation of components.
Innovation Solution
The apparatus employs a configuration with an infrared drier and hot air supplier, along with a transfer roller having steps to prevent contamination, and includes height and tension adjustment mechanisms to maintain uniform drying and component quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional drying chamber is used for reel-to-reel substrate drying, then the drying process can be performed, but uniform heat transfer is difficult to achieve and temperature distribution varies between central and edge portions
Solution Approach 1:
The drying chamber is divided into multiple heating zones with independent temperature control. Multiple infrared heaters are arranged at different positions (central and edge regions) to segment the heating function, allowing each zone to be controlled independently to achieve uniform temperature distribution across the substrate surface.
Solution Approach 2:
Different regions of the drying chamber are equipped with different heating intensities and control parameters. The central and edge portions have customized heating zones with adjusted power and temperature settings to compensate for heat distribution variations, ensuring each local region receives appropriate heat treatment for uniform drying.
2Manufacturing precision
If a conventional drying chamber is used, then drying can be performed, but maintaining uniform substrate height is difficult and local drying occurs
Solution Approach 1:
A height detection device continuously monitors substrate height during the drying process and provides feedback to the control system. The control system adjusts heating power and airflow parameters in real-time based on detected height variations, ensuring uniform substrate height and preventing local drying defects.
Solution Approach 2:
The drying system dynamically adjusts heating intensity and airflow rates during the drying process based on real-time substrate state. The heating zones can independently modulate their output, and the substrate table can adjust its position, allowing the system to adapt to changing conditions and maintain uniform drying throughout the process.
3Ease of operation
If a conventional transfer device is used, then substrate transfer is possible, but PSR ink adheres to the transfer device causing contamination
Solution Approach 1:
A release film is introduced as an intermediary between the substrate and the transfer device. The substrate is transferred onto the release film, which prevents direct contact between the PSR ink and the transfer device, thereby eliminating contamination while maintaining efficient substrate transfer capability.
4Productivity
If drying parameters are increased to improve drying efficiency, then drying speed increases, but temperature distribution becomes more uneven and local drying defects occur
Solution Approach 1:
The drying chamber is divided into multiple independently controllable heating zones. Each zone can operate at optimized power levels simultaneously, allowing the overall drying efficiency to be high while each local zone maintains uniform temperature distribution, preventing local drying defects.
Solution Approach 2:
The system uses multiple heating parameters (different power levels, temperatures, and heating intensities) across different zones and time periods. By dynamically changing these parameters in each zone based on real-time feedback, the system achieves both high drying efficiency and uniform drying quality simultaneously.
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
Ensures uniform drying and prevents contamination by using infrared light and hot air in conjunction with a specially designed transfer roller, while maintaining consistent component height and tension, thereby improving drying efficiency and quality.
Implementation Method 1
an infrared drier for irradiating infrared light toward the component
Implementation Method 2
a hot air supplier for supplying hot air between the infrared drier and the component
Data Source
AI summary
Disclosed is an apparatus for drying a component transferred in a reel-to-reel method. The apparatus for drying a component transferred in a reel-to-reel method includes an uncoiler and a recoiler, both for transferring the component, a drying chamber disposed between the uncoiler and the recoiler and drying the component, wherein the drying chamber includes an inner space, a transfer roller for transferring the component; an infrared drier for irradiating infrared light toward the component, and a hot air supplier for supplying hot air between the infrared drier and the component.