Transfer Printing Roller for Uniform OLED Encapsulation
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Solution Overview
Problem
Current encapsulating processes for OLED displays face challenges with high manufacturing costs due to inadequate adhesion of protective films, high-precision requirements, and non-uniform glue coating, leading to defects and increased production costs.
Innovation Solution
A transfer roller with an absorbing layer and through-holes is used in conjunction with a coating system that includes a glue liquid storage device, input device, and coating roller, utilizing micropores and absorbing particulates to ensure uniform glue distribution and impurity absorption, along with a control system for precise glue application and surface adaptation to panel features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a conventional coating system with separate coating head and drying sections is used, then the coating process can be completed, but the system requires significant floor space and has complex mechanical structures
Solution Approach 1:
The patent combines the coating head, drying section, and transfer printing roller into a single integrated coating device. The coating head includes a drying section with a drying element that directly contacts the film during coating, eliminating the need for separate drying chambers or sections. This integration significantly reduces the overall footprint and simplifies the mechanical structure while maintaining effective coating and drying functions.
Solution Approach 2:
The transfer printing roller serves multiple functions: it applies the coating material to the film, transfers the coated film through the drying section, and initially supports the film before lamination. This multi-functional design eliminates the need for separate coating rollers, transfer rollers, and support structures, thereby reducing device complexity and space requirements.
2Reliability
If adhesive is applied immediately before lamination, then the lamination process can proceed, but the adhesive may dry out or become contaminated before use
Solution Approach 1:
The coating head applies the adhesive coating to the film in advance, and the integrated drying section immediately dries the coating as it is applied. This preliminary coating and drying action ensures the adhesive is prepared and protected before the lamination step, preventing drying out or contamination during transfer. The system maintains the adhesive in a controlled state from coating through to lamination.
3Adaptability or versatility
If the film is handled multiple times during the process, then various operations can be performed, but contamination and defects increase
Solution Approach 1:
The patent merges the coating, drying, and transfer functions into a single continuous operation within the integrated coating device. The film passes through the coating head and drying section in one continuous motion, then is transferred directly to the lamination station without intermediate handling steps. This reduces the number of times the film is picked up and placed down, minimizing contamination risks while maintaining process flexibility.
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 reduces manufacturing costs by improving adhesion, achieving high-speed, high-uniformity glue coating, and extending the life of coating materials through efficient impurity management and precise glue application, thereby enhancing the encapsulation of OLED displays.
Implementation Method 1
a roller (220) referred to as a transfer printing roller for transferring the packaged film (203) from the packaging station (200) to the recapping station (300)
Data Source
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AI summary
An encapsulating glue film coating system and a transfer roller thereof, and a method of forming an encapsulating glue film are provided. The encapsulating glue film coating system comprises: a support platform configured to carry a display panel to be encapsulated; a glue liquid storage device configured to provide a glue liquid; a glue liquid input device mounted on the support platform and configured to receive the glue liquid from the glue liquid storage device; and a transfer roller configured to receive the glue liquid from the glue liquid input device. The transfer roller is configure to transfer glue liquid to a coating roller and comprises: a roller body; an absorbing layer disposed around the roller body, the absorbing layer having a plurality of micropores communicating with external environment; and a transfer layer disposed around the absorbing layer for transferring glue liquid to a coating roller, wherein the transfer layer is provided with a plurality of first through-holes, so as to allow impurities to enter the micropores in the absorbing layer. With the encapsulating glue film coating system, glue liquid can be uniformly applied onto the display panel.