Light-Emitting Panel Functional Layer Thickness Compensation
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Solution Overview
Problem
Existing light-emitting panels, such as organic EL display panels, face issues with uneven thickness in functional layers formed using vacuum film forming devices like magnetron sputtering and evaporation devices, leading to variations in luminance due to differences in optical distance and resistance values between regions.
Innovation Solution
A light-emitting panel with a substrate and a light-emitting functional multilayer comprising first and second functional layers, where the thickness of one layer in a first region is smaller than in a second region, and vice versa, to reduce thickness differences and improve uniformity, using distinct placement positions of magnetrons or evaporation sources in film forming devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum film forming devices (magnetron sputtering or evaporation devices) are used to form functional layers, then the light-emitting panel can be manufactured with required functional layers, but uneven thickness occurs in the functional layers leading to luminance variations
Solution Approach 1:
The patent applies local quality by creating different thickness distributions in different functional layers. Specifically, the first functional layer has a first thickness distribution while the second functional layer has a second thickness distribution that compensates for the first. This means that in regions where the first layer is thinner, the second layer is made thicker, and vice versa, thereby achieving overall thickness uniformity through localized thickness variation in individual layers.
Solution Approach 2:
The patent employs asymmetry by intentionally creating asymmetric thickness distributions in the functional layers. Rather than attempting to make each layer uniformly thick, the invention uses asymmetric thickness profiles where layers are deliberately made non-uniform in complementary ways. This asymmetric approach allows the combined multilayer structure to achieve uniformity while individual layers maintain controlled non-uniformity.
2Illumination intensity
If multiple functional layers are formed with different thickness distributions, then luminance uniformity is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies parameter changes by modifying the thickness distribution parameter of functional layers during the film formation process. By controlling deposition parameters such as magnetron positioning, power distribution, or evaporation source movement, the invention achieves different thickness distributions in different layers. This parameter control is implemented through adjustments in the film forming device operation rather than complex mechanical modifications.
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 minimizes uneven thickness and luminance variations by adjusting the thickness distribution of functional layers, resulting in improved uniformity and performance across the panel.
Implementation Method 1
The transparent conductive layer and a hole injection layer as layers included in a functional multilayer are formed with use of a vacuum film forming device such as a magnetron sputtering device
Implementation Method 2
The similar problem occurs also in the case where film formation is performed with use of an evaporation device
Data Source
AI summary
A light-emitting panel includes: a substrate and a light-emitting functional multilayer formed on the substrate, wherein the light-emitting functional multilayer including a first functional layer and a second functional layer, a thickness of part of the first functional layer positioned in a first light-emitting region is smaller than a thickness of part of the first functional layer positioned in a second light-emitting region, a thickness of part of the second functional layer positioned in the first light-emitting region is greater than a thickness of part of the second functional layer positioned in the second light-emitting region, and when the light-emitting functional multilayer is viewed in a layering direction, the first light-emitting region and the second light-emitting region are adjacent or distant from each other in a direction perpendicular to the layering direction, and each include a plurality of pixels that are each composed of a plurality of adjacent sub-pixels.