Vertical Roll Orientation for Flexible Substrate Component Protection
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Solution Overview
Problem
Conventional roll-to-roll manufacturing methods for light emitting devices result in electronic components and sealing members being broken or deteriorated due to continuous loading during manufacturing, storage, and delivery, as the flexible substrates are typically held in a horizontal state, causing undue stress on these components.
Innovation Solution
The method involves winding a flexible component mounting substrate around a core and holding the core parallel to the vertical direction to minimize the load on electronic components and sealing members, thereby reducing the likelihood of breakage or deterioration, allowing for the use of materials with lower mechanical strength for sealing members and ensuring efficient assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flexible substrate is held in a horizontal state during manufacturing, storage, and delivery, then the manufacturing process is simple and efficient, but the electronic components and sealing members are subjected to continuous loading causing breakage or deterioration
Solution Approach 1:
The patent inverts the conventional horizontal holding approach by holding the roll vertically with the core in a vertical state. This inversion changes the load distribution from horizontal compression to vertical suspension, eliminating the harmful loading on electronic components and sealing members while maintaining manufacturing efficiency
Solution Approach 2:
The patent changes the orientation parameter from horizontal to vertical. By holding the core vertically instead of horizontally, the gravitational load is redistributed along the length of the substrate rather than compressing the components, thereby improving component integrity without sacrificing productivity
2Reliability
If stronger sealing members are used to withstand the loading, then component protection is improved, but the mechanical strength requirement increases material cost and complexity
Solution Approach 1:
The patent converts the harmful effect of gravitational loading into a beneficial suspension system. By holding the roll vertically, the weight of the substrate and components is supported by the core structure rather than being borne by the sealing members, allowing the use of softer materials with lower mechanical strength
Solution Approach 2:
The patent changes the loading condition parameter by altering the hold orientation. This parameter change reduces the mechanical strength requirement for sealing members from high to low, enabling the use of softer, more compliant materials that provide effective sealing without requiring high structural strength
Data Source
AI summary
Provided is a method of managing a component mounting substrate that can be used in a roll-to-roll process, without breaking or deteriorating electronic components mounted thereon. In the method of winding, around a core, a flexible component mounting substrate on which a plurality of electronic components are mounted and managing the component mounting substrate as a roll, the roll is held such that the core of the roll is parallel to a vertical direction.