Display Panel Organic Layer Formation via Wet Process and Resist Masking
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Solution Overview
Problem
Existing display panel manufacturing methods face challenges in achieving high-resolution displays with reduced crosstalk and cost-effectiveness, particularly in forming organic compound layers without using fine metal masks.
Innovation Solution
A manufacturing method involving a wet process, such as inkjet or spin coating, where resist masks are used to selectively form and process layers of organic compounds, preventing unnecessary layer extension and minimizing crosstalk between light-emitting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a continuous organic substance layer is formed throughout the display region without using a fine metal mask, then manufacturing cost is reduced and device complexity is simplified, but crosstalk occurs between adjacent pixels
Solution Approach 1:
The patent divides the organic substance layer into discrete regions corresponding to individual pixel openings. By forming the organic layer only within the boundaries of each pixel opening rather than as a continuous film, the patent eliminates crosstalk between adjacent pixels while maintaining cost-effective manufacturing without fine metal masks.
Solution Approach 2:
The patent applies different properties to different regions by controlling the organic substance layer formation locally within each pixel opening. The organic layer is present only where needed (within pixel openings) and absent in inter-pixel regions, creating local quality differences that prevent crosstalk while simplifying overall manufacturing.
2Manufacturing precision
If the nozzle diameter is miniaturized to fit the opening portion size for high-resolution display, then display resolution is improved, but manufacturing difficulty and device complexity increase
Solution Approach 1:
Instead of miniaturizing the nozzle to fit the pixel opening, the patent inverts the approach by using a larger nozzle that deposits organic material across multiple pixel openings, then using photolithography to define the precise pixel boundaries. This reverses the traditional sequencing and avoids nozzle miniaturization complexity while achieving high resolution.
Solution Approach 2:
The patent performs preliminary deposition of the organic substance layer across the entire display region before applying the photomask and performing photolithography. This preliminary action allows using a larger, simpler nozzle, and the subsequent photolithography step precisely defines the pixel boundaries without requiring nozzle miniaturization.
3Manufacturing precision
If photolithography is used to process organic compound layers after wet process deposition, then manufacturing precision and crosstalk reduction are improved, but additional processing steps increase device complexity
Solution Approach 1:
The patent uses photolithography to define pixel boundaries, and the resulting patterned organic layer structure serves multiple subsequent functions: it defines emission regions, prevents crosstalk, and guides further material deposition. This self-service approach consolidates multiple functions into the photolithography step, justifying the added processing complexity.
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 production of high-resolution display panels with reduced crosstalk and lower costs by precisely controlling the formation of light-emitting layers, ensuring good functionality and efficiency.
Implementation Method 1
a light-emitting layer is deposited by a vacuum evaporation method to be a continuous film
Data Source
AI summary
A novel display panel having good functionality is provided. Provided are a display panel and a manufacturing method of the display panel, including forming an insulator including at least a first opening portion and a second opening portion over a substrate, forming a first material layer including an organic compound of a first light-emitting element in the first opening portion and a second material layer including an organic compound of a second light-emitting element in the second opening portion by a wet process, forming a first resist mask and a second resist mask respectively over the first material layer and the second material layer selectively, and forming a third material layer by processing the first material layer with the first resist mask, and forming a fourth material layer by processing the second material layer with the second resist mask. As the organic compounds of the light-emitting elements, a hole-transport material, a light-emitting material, and the like can be used.