Roll-to-Roll Fabricating System Turning Unit for OLED Deposition
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Solution Overview
Problem
The existing methods for fabricating organic light emitting devices are inefficient due to the need for multiple deposition devices and transfer devices, which increase installation costs and require synchronized processes, leading to potential damage of the deposited layers and material loss.
Innovation Solution
A roll-to-roll fabricating system with a turning unit is introduced, featuring deposition units with deposition drums and evaporators, and a turning unit with moveable rolls that prevent contact between the deposition surface and other structures, allowing for continuous inline processing and synchronization of deposition units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple deposition devices and transfer devices are used to fabricate organic light emitting devices, then the device structure can be completed, but installation costs increase and installation space is required
Solution Approach 1:
The patent combines multiple deposition devices into a single integrated deposition device with multiple deposition chambers. The transfer devices are eliminated by implementing a continuous roll-to-roll process where the substrate moves continuously through the deposition chambers without interruption. This merging reduces the number of separate components, lowering installation costs and space requirements while maintaining the capability to fabricate complete organic light emitting device structures.
Solution Approach 2:
The deposition device is segmented into multiple deposition chambers within a single integrated structure. Each chamber can perform deposition of different layers independently, allowing the complex multi-layer organic light emitting device structure to be built sequentially without requiring multiple separate devices. This segmentation enables functional division while maintaining physical integration.
2Manufacturing precision
If synchronized deposition and transfer processes are performed, then multiple layers can be deposited, but the process complexity increases and material loss occurs due to empty space during transfer
Solution Approach 1:
The patent implements a continuous roll-to-roll deposition process where the substrate moves continuously through multiple deposition chambers without interruption or transfer steps. This eliminates the empty space problems and synchronization requirements of batch processing. The continuous motion allows uninterrupted deposition of multiple layers, reducing material loss and process complexity while maintaining manufacturing precision.
3Ease of operation
If the deposition surface of the film contacts the roll during turning, then the film can be transferred, but the deposited layer is damaged
Solution Approach 1:
The patent introduces a release film as an intermediary layer between the deposited film and the turning roll. The release film allows the film to be transferred and turned without the deposited surface directly contacting the roll. This intermediary layer protects the integrity of the deposited layers while still enabling the mechanical transfer and turning operations necessary for continuous processing.
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 system enables rapid fabrication of organic light emitting devices by preventing damage to the deposited layers, minimizing material loss, and optimizing the deposition process through synchronized operation and cooling of the film, thus reducing installation costs and improving efficiency.
Implementation Method 1
one or more evaporators disposed to face the deposition drum, and configured to deposit the film wound on the deposition drum
Implementation Method 2
The deposition drum is formed of a material such as a metal having a high thermal conductivity, and cools the film having its temperature increased during a deposition process to prevent damage of the film due to a temperature increase
Data Source
AI summary
In a roll to roll fabricating system, a plurality of deposition units are provided, and a turning unit is disposed between the deposition units. The deposition units include: a deposition drum on which a film is wound; and one or more evaporators disposed to face the deposition drum, and configured to deposit the film wound on the deposition drum. The turning unit includes a plurality of turning rolls, and is configured to turn the film output from one deposition unit, to guide the film, and to supply the film to another deposition unit.