Segmented OVJP Print Bar for Non-Planar Substrate Alignment
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Solution Overview
Problem
Current organic vapor jet (OVJP) deposition techniques struggle with maintaining precise control over the distance between print heads and substrates, especially on non-planar surfaces, leading to inefficiencies in large-scale OLED fabrication due to the inability to accommodate substrate flatness variations.
Innovation Solution
A segmented print bar with multiple independent print head segments, equipped with distance sensors and actuators, allows for precise adjustment and alignment of print heads to maintain a consistent distance from the substrate, accommodating non-planar surfaces and enabling efficient large-scale OLED production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional fixed print bar is used for OVJP deposition, then the device structure is simple, but the manufacturing precision deteriorates due to inability to maintain consistent print head-to-substrate distance on non-planar surfaces
Solution Approach 1:
The print bar is divided into multiple independently controllable segments or print heads, each capable of adjusting its position relative to the substrate. This segmentation allows each print head to adapt to local surface variations, maintaining precise deposition control across non-planar substrates while managing overall system complexity through modular design
Solution Approach 2:
The print bar incorporates dynamic adjustment mechanisms such as actuators and sensors that enable real-time modification of print head positions. This dynamic capability allows the system to compensate for substrate flatness variations during the deposition process, maintaining manufacturing precision without requiring a completely complex rigid structure
2Manufacturing precision
If the print bar is designed to accommodate non-planar substrates with adjustment mechanisms, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The system incorporates sensors that continuously monitor the distance between print heads and the substrate surface, providing real-time feedback to control systems. This feedback mechanism enables automatic adjustment of print head positions to maintain consistent deposition parameters, improving deposition uniformity while managing complexity through automated control rather than purely mechanical solutions
Solution Approach 2:
The patent replaces purely mechanical adjustment systems with a combination of sensing technology and controlled actuation. By using sensors to detect substrate topography and electronically controlling print head positions, the system achieves precise deposition control with reduced mechanical complexity compared to purely mechanical adjustment mechanisms
3Productivity
If a single large print head is used to cover the entire substrate, then the device complexity is low, but the productivity decreases due to inability to efficiently handle large-area deposition
Solution Approach 1:
The deposition system is divided into multiple print heads arranged in arrays or banks, allowing parallel deposition across different regions of the substrate. This segmentation enables simultaneous deposition operations, significantly increasing productivity for large-area substrates while managing complexity through modular, independently controllable print head units
Solution Approach 2:
Multiple print heads are combined in a coordinated system that operates in unison to deposit materials across the entire substrate surface. By merging the capabilities of multiple print heads and coordinating their operations, the system achieves high-speed large-area deposition that would be impossible with a single print head, while maintaining manageable complexity through integrated control
Data Source
AI summary
Implementations of the disclosed subject matter provide a print bar for organic vapor jet (OVJP) deposition is provided that includes a plurality of n print head segments, where each of the plurality of print head segments may have an OVJP print head. The print bar may include a plurality of distance sensors, where each of the plurality of distance sensors may be configured to measure a distance between a substrate disposed below the print bar and a portion of at least one of the print head segments. The print bar may include a plurality of not more than n+1 actuators configured to adjust at least one of a position and an orientation of one or more of the plurality of print head segments based upon one or more distances between the substrate and the print bar measured by one or more of the plurality of distance sensors.