Light Emitting Element Intermediate Layer Protection

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Solution Overview

Problem

The existing methods for manufacturing light-emitting elements, such as those described in PTL 1, do not adequately protect the charge transport layer below the light-emitting layer during the development process, leading to potential damage.

Innovation Solution

A method involving the formation of an intermediate layer with a first resin on the charge transport layer, followed by a light-emitting layer with a second resin and photosensitive material, where the intermediate and light-emitting layers are exposed and developed using solutions with differing solubility properties to minimize damage to the charge transport layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a resist layer is formed on an organic compound layer including a light-emitting layer and developed, then the light-emitting layer pattern can be formed, but the charge transport layer below the light-emitting layer is damaged by the developing solution

Engineering Contradiction:

Improvelight-emitting layer pattern formationVSAvoiddamage to charge transport layer

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

An intermediate layer is introduced between the charge transport layer and the light-emitting layer. This intermediate layer acts as a protective barrier that prevents the developing solution from reaching and damaging the charge transport layer during the development process, while still allowing the light-emitting layer pattern to be formed through the resist layer above it.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The intermediate layer is formed in advance before the resist layer and light-emitting layer are deposited. This preliminary structure is prepared with appropriate solubility characteristics that enable it to protect underlying layers during subsequent development operations without interfering with the intended patterning process.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If the intermediate layer is made water-soluble for easy removal, then processing becomes simpler, but the charge transport layer remains vulnerable to developing solution damage

Engineering Contradiction:

Improveintermediate layer processingVSAvoiddamage to charge transport layer

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The intermediate layer is designed with specific solubility parameters that differ from both water-soluble and organic-soluble extremes. By carefully selecting the solubility characteristics of the intermediate layer material, it provides adequate protection during development while maintaining appropriate removability through controlled chemical properties rather than extreme water solubility.

Inventive Principle:

Principle #35Parameter changes

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 effectively reduces damage to the charge transport layer by using solubility differences in the developing solutions to protect the light-emitting layer, ensuring precise patterning and maintaining the integrity of the underlying layers.

Implementation Method 1

exposing the intermediate layer and the light-emitting layer in a predetermined pattern to obtain an exposed intermediate layer and an exposed light-emitting layer

Methodology Applied

Scientific EffectPhotochemical reaction: Photography

Implementation Method 2

a solubility of a second portion of the exposed intermediate layer dissolved in the developing solution and a solubility of a first portion of the exposed light-emitting layer dissolved in the developing solution are different from each other

Methodology Applied

Scientific EffectSolubility: Solvation

Data Source

PatentUS20240196719A1Method for producing light emitting element, and light emitting element

Publication Date: 2024.06.13 SHARP KK

AI summary

A method for manufacturing a light-emitting element includes a) forming an intermediate layer containing a first resin on a charge transport layer, b) forming a light-emitting layer containing a second resin, a second photosensitive material, and a first luminescent material on the intermediate layer, c) exposing the intermediate layer and the light-emitting layer in a predetermined pattern to obtain an exposed intermediate layer and an exposed light-emitting layer, respectively, and d) developing the exposed intermediate layer and the exposed light-emitting layer with a developing solution. A solubility of a second portion of the exposed intermediate layer dissolved in the developing solution and a solubility of a first portion of the exposed light-emitting layer dissolved in the developing solution are different from each other.