Grooved Heatable Substrate for Uniform OLED Vapor Deposition
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Solution Overview
Problem
Vapor deposition in OLED manufacturing often results in shadow effects and uneven film thickness due to inappropriate angles of the vapor deposition source, leading to suboptimal light-emitting material layer formation.
Innovation Solution
A vapor deposition source with grooves on a heatable substrate, where the grooves contain vapor deposition material and are aligned with pre-vapor deposition regions on a second substrate to allow for precise and uniform deposition at a 90-degree angle, reducing shadow effects and ensuring even film thickness across different color layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a vapor deposition source is used with a small or large deposition angle, then the deposition process can be completed, but shadow effects and uneven film thickness occur
Solution Approach 1:
The substrate is divided into multiple regions with different groove depths. Specifically, the substrate includes a first region with a first groove depth and a second region with a second groove depth different from the first. This segmentation allows different portions of the substrate to receive vapor deposition material at different effective angles, thereby eliminating shadow effects and achieving uniform film thickness across the entire substrate surface.
Solution Approach 2:
Different regions of the substrate are given different local properties through varying groove depths. The first region has a first groove depth optimized for its specific deposition requirements, while the second region has a second groove depth optimized for its requirements. This local quality variation ensures that each region receives appropriate deposition angles tailored to its position, preventing shadow effects and achieving overall uniformity.
2Manufacturing precision
If the vapor deposition source angle is not optimized, then the deposition process is simple, but the light-emitting material layer formation is suboptimal
Solution Approach 1:
The substrate is segmented into multiple regions with different groove depths to optimize light-emitting material layer formation. By dividing the substrate into a first region with a first groove depth and a second region with a second groove depth, the invention achieves superior deposition quality without requiring complex external adjustment mechanisms, thus balancing manufacturing precision with device complexity.
Solution Approach 2:
The groove depth variations are pre-formed on the substrate before the vapor deposition process. This preliminary action of creating region-specific groove depths during substrate fabrication eliminates the need for complex real-time angle adjustments during deposition, thereby improving material layer quality while maintaining relatively simple deposition equipment.
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 enhances the uniformity and quality of organic light-emitting material layers, reducing shadow effects and achieving consistent film thickness, thereby improving the overall performance of OLED displays.
Implementation Method 1
the first substrate is heated to vaporize the vapor deposition material in the grooves, so as to form an organic light-emitting material layer
Implementation Method 2
the first substrate is heated to vaporize the vapor deposition material in the grooves
Data Source
AI summary
A source to facilitate precise vapor deposition in processes to obtain organic light emitting diodes (OLEDs) in a display panel, includes forming a plurality of grooves on a first substrate; in filling organic light emitting materials into the grooves and providing a second substrate to receive the vaporized organic light emitting materials. The first substrate is aligned with the second substrate and the first substrate is heated to vaporize the organic light emitting materials in the grooves. The vapor deposition regions of the second substrate form an organic light emitting material layer after the deposition, the layer can then be used in an OLED display panel. The shadow effect is greatly reduced, a method for the procedure is also disclosed.