Display Device Light-Emitting Layer Patterning via Capillary Ink Feeding
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Solution Overview
Problem
Existing display device manufacturing methods using a capillary phenomenon to pattern light-emitting layers result in high partitions that can interfere with the application of a common electrode, leading to potential interruptions at inclined surfaces.
Innovation Solution
A display device manufacturing method involving the formation of a first light layer and a mask pattern with openings over sub-pixel regions, followed by the removal of the first light layer below the openings and the feeding of ink containing a second light material through the openings to form a second light layer, without leaving a high partition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a high partition is provided to cause capillary phenomenon for separately patterning light-emitting layers, then light-emitting layers can be separately patterned, but a high partition remains that may interrupt the common electrode application
Solution Approach 1:
The patent extracts and removes the harmful high partition structure after it has served its purpose of enabling capillary phenomenon for separate patterning of light-emitting layers. The partition is temporarily formed to guide ink flow, then removed to eliminate the obstacle for common electrode application, thus resolving the contradiction between achieving patterning precision and avoiding harmful remnants.
Solution Approach 2:
The partition structure is formed in advance before the patterning process to enable the capillary phenomenon. This preliminary action allows the system to achieve precise separate patterning of light-emitting layers, and the partition is subsequently removed to eliminate its harmful effect, demonstrating preliminary action followed by removal of the temporary structure.
2Manufacturing precision
If ink is fed to below the opening to form a second light layer using capillary phenomenon, then separate patterning is achieved, but the process complexity increases
Solution Approach 1:
The mask pattern serves as an intermediary structure that enables the capillary phenomenon to occur in a controlled manner. By introducing this intermediate element, the patent achieves precise separate patterning of light-emitting layers while managing the process complexity through a systematic approach involving mask formation, ink feeding, and mask removal.
Solution Approach 2:
The patent replaces traditional mechanical patterning methods with a capillary-driven ink feeding mechanism. Instead of using complex mechanical alignment and deposition systems, the invention uses the natural capillary action of ink to achieve precise patterning, thereby reducing mechanical complexity while maintaining manufacturing precision.
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 method enables the separate patterning of light-emitting layers using a capillary phenomenon without leaving a high partition, ensuring uninterrupted application of a common electrode and improved display device performance.
Implementation Method 1
a technique is known in which regarding light-emitting layers of a plurality of colors of RGB continuously formed over a plurality of pixels, light-emitting layers of the second and third colors are separately painted using a capillary phenomenon
Data Source
AI summary
A display device includes a first light-emitting layer formed continuously over a plurality of first pixels, and a second light-emitting layer formed continuously over a plurality of second pixels and not overlapping the first light-emitting layer in a plan view. The second light-emitting layer includes a solution drop material, and the first light-emitting layer is formed overlapping a part of an outer peripheral portion of each pixel in a plan view.