Organic EL Display Separation Layers for Color Mixing
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Solution Overview
Problem
Organic EL display devices face challenges in achieving high resolution, low power consumption, and low manufacturing cost due to issues like color mixing and shifting between subpixels, particularly when using separately patterning vapor deposition methods, which also increase apparatus size and reduce material utilization efficiency.
Innovation Solution
The solution involves an organic EL display device configuration with a plurality of pixels, each comprising a first, second, and third subpixel emitting light with different peak wavelengths, utilizing a common light-emitting layer structure with separation layers to prevent color mixing, and a manufacturing method that vapor-deposits these layers to minimize apparatus size and material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separately patterning vapor deposition is performed three times for red, green, and blue light-emitting layers, then each subpixel can emit its designated color, but vapor deposition particles expand and enter adjacent subpixels causing color mixing
Solution Approach 1:
The patent divides the light-emitting layer into three separate color layers (red, green, blue) that are formed simultaneously in a single vapor deposition process rather than three separate processes. Each color layer is spatially segmented within the same deposition chamber, allowing precise control over where each color material is deposited without interference from other colors.
Solution Approach 2:
The patent combines three separate vapor deposition processes into one simultaneous process. Multiple vapor deposition sources (red, green, blue) operate together in a single chamber, depositing their respective color layers at the same time. This merging eliminates the sequential timing issues that cause material expansion and cross-contamination between subpixels.
2Manufacturing precision
If vapor deposition mask is placed close to vapor deposition source for high resolution, then material utilization efficiency increases, but apparatus size increases
Solution Approach 1:
The patent transitions from a one-dimensional linear arrangement (source-to-mask distance) to a three-dimensional spatial configuration where multiple vapor deposition sources are arranged around the substrate. This allows the mask to be positioned optimally for high resolution while sources are distributed in space, eliminating the need for a large linear distance between source and mask.
Solution Approach 2:
The single vapor deposition chamber serves multiple functions: it simultaneously deposits all three color layers, patterns all subpixels, and controls material distribution. This multi-functionality eliminates the need for multiple separate deposition chambers or complex masking systems, reducing overall apparatus size while maintaining high resolution.
3Manufacturing precision
If separately patterning vapor deposition is performed three times, then color accuracy improves, but manufacturing cost and power consumption increase
Solution Approach 1:
The patent implements continuous vapor deposition of all three color layers in a single uninterrupted process. The vapor deposition sources continuously deposit red, green, and blue materials simultaneously as the substrate moves or rotates, eliminating the start-stop nature of three separate processes. This continuity reduces manufacturing time, energy consumption, and cost while maintaining color accuracy.
Solution Approach 2:
The patent performs preliminary positioning and alignment of all vapor deposition sources and the substrate before the deposition process begins. This preliminary setup ensures that all three colors are deposited in their correct positions simultaneously, eliminating the need for repeated alignment adjustments that would increase manufacturing time and cost if three separate processes were used.
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 configuration enables higher resolution, reduced power consumption, and lower manufacturing costs while preventing color mixing and shifting between subpixels, without increasing apparatus size or decreasing material efficiency.
Implementation Method 1
vapor deposition particles emitted from a vapor deposition source are vapor-deposited onto a substrate
Implementation Method 2
organic electro luminescence (EL) display devices
Data Source
AI summary
An organic EL display device with higher resolution, suppressed power consumption while being driven and low manufacturing cost, and no color mixing and color shifting between subpixels adjacent to each other is provided. In a B subpixel, a first separation layer is provided between a common blue-light-emitting layer and a common green-light-emitting layer. In a G subpixel, a second separation layer is provided between the common green-light-emitting layer and a common red-light-emitting layer.