Light-Emitting Device Shadow Mask Merging
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Solution Overview
Problem
The manufacturing of light-emitting devices with multiple color light-emitting layers requires high accuracy in shadow mask alignment, leading to reduced yield and increased complexity, particularly in achieving full-color displays with red, green, and blue light emission.
Innovation Solution
A light-emitting device structure comprising multiple light-emitting elements with specific layer configurations, including transparent conductive layers, hole-injection, hole-transport, and electron-transport layers, optimized for efficient light emission in red, green, and blue wavelength ranges, allowing for shared layers and reduced manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If light-emitting layers for different colors are deposited side by side using shadow mask, then full-color display capability is achieved, but alignment accuracy requirements increase and manufacturing yield decreases
Solution Approach 1:
The patent merges the deposition process for different colored light-emitting layers by using a single shadow mask with multiple openings instead of separate masks for each color. This combining of multiple deposition steps into one process reduces alignment complexity and manufacturing precision requirements while maintaining full-color display capability.
Solution Approach 2:
The shadow mask is designed with multi-functionality, serving as a single template that defines patterns for multiple different colored light-emitting layers simultaneously. This universal mask replaces what would otherwise require multiple specialized masks, thereby reducing the overall alignment accuracy requirements across the manufacturing process.
2Reliability
If multiple separate shadow masks are used for different color layers, then color purity is maintained, but device complexity and manufacturing steps increase
Solution Approach 1:
Multiple shadow masks that would traditionally be used separately for different color layers are merged into a single multi-opening shadow mask. This consolidation maintains the ability to produce pure colors through precise opening design while reducing the total number of masks and associated alignment steps in the manufacturing process.
3Manufacturing precision
If higher alignment accuracy is required for shadow mask openings, then definition quality improves, but productivity decreases
Solution Approach 1:
The patent combines the definition of multiple light-emitting layer patterns into a single shadow mask alignment process. By depositing all colored layers through one mask rather than sequentially aligning multiple masks, the system achieves high definition quality without the compounding alignment errors that would reduce productivity.
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 approach enhances productivity and reduces power consumption while maintaining high luminous efficiency and reliability, enabling efficient extraction of light in desired wavelength ranges for full-color displays.
Implementation Method 1
a light-emitting layer capable of emitting light by application of an electric field
Implementation Method 2
a hole-transport layer, an electron-transport layer
Data Source
AI summary
To provide a novel light-emitting device with high productivity, the light-emitting device includes a first light-emitting element, a second light-emitting element, and a third light-emitting element. In the first light-emitting element, a first lower electrode, a first transparent conductive layer, a first light-emitting layer, a second light-emitting layer, and an upper electrode are stacked in this order. In the second light-emitting element, a second lower electrode, a second transparent conductive layer, the first light-emitting layer, the second light-emitting layer, and the upper electrode are stacked in this order. In the third light-emitting element, a third lower electrode, a third transparent conductive layer, the second light-emitting layer, and the upper electrode are stacked in this order. The first transparent conductive layer includes a first region. The second transparent conductive layer includes a second region as thick as the third transparent conductive layer. The first region is thicker than the second region.