Inkjet Printed Pixel Defining Layer for OLED Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming micro-patterns in organic electroluminescence devices, such as those used in semiconductor devices, are costly and inefficient, particularly in forming precise pixel defining layers and organic light-emitting layers, due to the use of photoresist processes which are time-consuming and result in defects like luminous efficiency reduction and color mixing.
Innovation Solution
A method involving the formation of color patterns on a substrate followed by the creation of a pixel defining layer using inkjet printing, where the color patterns serve as barrier ribs to achieve precise and desired shapes, reducing the need for photoresist processes and enhancing pattern precision and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photoresist processes are used to form pixel defining layers and organic light-emitting layers, then micro-patterns can be formed, but the manufacturing cost increases and manufacturing precision decreases due to defects like luminous efficiency reduction and color mixing
Solution Approach 1:
The patent extracts and eliminates the photoresist process from the manufacturing sequence by directly forming pixel defining layers through inkjet printing after color pattern formation. This removes the source of defects (luminous efficiency reduction and color mixing) while maintaining micro-pattern precision and reducing manufacturing cost.
Solution Approach 2:
The patent performs preliminary formation of color patterns on the substrate before forming the pixel defining layer. The color patterns serve as pre-established barriers that guide and define the pixel defining layer formation, eliminating the need for subsequent photoresist processes and achieving both high precision and cost reduction.
2Manufacturing precision
If photoresist processes are used to form micro-patterns, then pixel defining layers can be formed, but time is lost due to the time-consuming nature of the process
Solution Approach 1:
The patent removes the time-consuming photoresist process entirely by using inkjet printing to directly form pixel defining layers on the substrate after color pattern formation. This eliminates multiple process steps (photoresist coating, exposure, development, etching) while maintaining precise pixel defining layer formation.
Solution Approach 2:
The patent replaces the mechanical/photochemical photoresist process system with a direct inkjet printing system. The inkjet printing process uses controlled material deposition rather than photoresist chemistry, significantly reducing manufacturing time while achieving the same or better precision in pixel defining layer formation.
3Reliability
If conventional methods are used to form pixel defining layers, then layers can be formed, but material loss occurs and luminous efficiency is reduced
Solution Approach 1:
The color patterns themselves serve as self-formed barrier ribs that automatically define the pixel boundaries. The pixel defining layer is deposited only where needed through inkjet printing, with the color patterns providing inherent guidance and containment, eliminating material loss and preventing color mixing without requiring additional photoresist materials.
Solution Approach 2:
The patent applies pixel defining layer material locally only where needed through inkjet printing, rather than coating the entire substrate with photoresist. The material is deposited precisely in the spaces between color patterns, reducing overall material usage and preventing unwanted material accumulation that would cause luminous efficiency reduction and color mixing.
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 allows for the formation of more precise micro-patterns at a lower cost by using inkjet printing to form pixel defining layers between color patterns, reducing material loss and improving luminous efficiency by preventing color mixing and maintaining desired shapes.
Implementation Method 1
forming a pixel defining layer using inkjet printing
Implementation Method 2
the color patterns serve as barrier ribs to achieve precise and desired shapes
Data Source
AI summary
A method of manufacturing an organic electroluminescence device is disclosed. In one aspect, the method includes forming color patterns on a substrate, and forming a pixel defining layer between the color patterns.