Modular Gas Enclosure Assembly for Low-Volume Inert OLED Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in scaling OLED printing technology to larger substrate sizes while maintaining an inert, particle-free environment, which is essential for producing high-quality OLED panels with minimal reactive species and particle contamination, as existing solutions struggle to provide a hermetically sealed, accessible, and efficient gas enclosure system for large-format OLED printing.
Innovation Solution
A gas enclosure assembly that integrates sealable frame members, ductwork, and a pressurized inert gas recirculation system, featuring a laminar flow filtration and purification system to maintain low levels of reactive species and particles, allowing for easy access and minimal downtime during processing and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large facility is hermetically sealed to maintain inert atmosphere for large-format OLED printing, then the printing environment can be maintained free of reactive species, but the engineering complexity and difficulty of sealing increase significantly
Solution Approach 1:
The gas enclosure is divided into multiple modular frame members (first frame member, second frame member, third frame member, fourth frame member) that can be assembled together to form a hermetically sealed enclosure. This segmentation allows the complex sealing task to be distributed across multiple manageable components, each contributing to the overall inert atmosphere maintenance without requiring a single complex seal.
2Ease of operation
If cabling, wiring and tubing are provided for OLED printing system operation, then the system can function, but significant dead volume is created where reactive species can be occluded
Solution Approach 1:
A manifold is introduced as an intermediary component to manage gas distribution to multiple devices within the enclosure. The manifold consolidates tubing connections and minimizes dead volume compared to individual tubing runs to each device. The patent specifically mentions that the manifold and tubing system is designed to minimize the volume where reactive species could be trapped, while still enabling operational control of the printing system.
3Ease of repair
If the gas enclosure is designed for easy maintenance access, then maintenance downtime can be minimized, but the hermetic seal integrity may be compromised
Solution Approach 1:
The frame members are designed as separate, modular units that can be disassembled and reassembled. This segmentation allows maintenance personnel to access internal components by separating frame members without compromising the overall seal integrity when properly reassembled. The design enables maintenance access while maintaining the ability to restore hermetic sealing through the modular frame structure.
Solution Approach 2:
The frame members are pre-configured with sealing surfaces and connection points that facilitate rapid reassembly after maintenance. The sealing gaskets and connection mechanisms are designed in advance to ensure that when frame members are reconnected, the hermetic seal is restored without requiring complex procedures, thus minimizing maintenance downtime while preserving seal integrity.
4Quantity of substance
If the enclosure volume is minimized to reduce inert gas requirements, then gas consumption is reduced, but access to enclosed devices becomes more difficult
Solution Approach 1:
The frame members are arranged in a spatial configuration that optimizes the use of enclosure volume. By strategically positioning frame members at corners and edges (first frame member at first corner, second frame member at second corner, etc.), the design maximizes the internal working space for device access while minimizing the overall enclosure volume. This dimensional arrangement ensures that the inert gas volume is reduced without unduly restricting access to enclosed devices.
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 solution enables the production of high-quality OLED panels on larger substrates by maintaining low reactive species and particle levels, ensuring extended panel longevity and meeting stringent cleanroom standards, while optimizing the working space and minimizing inert gas volume.
Implementation Method 1
a gas circulation system internal to a gas enclosure assembly, and a gas purification system external to the gas enclosure assembly
Implementation Method 2
Gas purification system external to the gas enclosure assembly that can be configured to remove reactive atmospheric species, such as water vapor, oxygen, and organic solvent vapors
Implementation Method 3
pressurized inert gas recirculation system
Implementation Method 4
laminar flow filtration and purification system to maintain low levels of reactive species and particles
Data Source
AI summary
The present teachings relate to various embodiments of an hermetically-sealed gas enclosure assembly and system that can be readily transportable and assemblable and provide for maintaining a minimum inert gas volume and maximal access to various devices and apparatuses enclosed therein. Various embodiments of an hermetically-sealed gas enclosure assembly and system of the present teachings can have a gas enclosure assembly constructed in a fashion that minimizes the internal volume of a gas enclosure assembly, and at the same time optimizes the working space to accommodate a variety of footprints of various OLED printing systems. Various embodiments of a gas enclosure assembly so constructed additionally provide ready access to the interior of a gas enclosure assembly from the exterior during processing and readily access to the interior for maintenance, while minimizing downtime.