Integrally Formed Buffer Layer and Spacer in OLED Devices
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Solution Overview
Problem
The existing organic electro-luminescence display devices face challenges in increasing production yield, reducing defect rates, and improving light efficiency, particularly due to limitations in the manufacturing process and aperture stability, which hinder the production of high-resolution displays.
Innovation Solution
The solution involves an organic electro-luminescence display device with a first substrate having sub-pixels, a first electrode, a buffer layer, and a spacer integrally formed, along with an organic light-emitting layer and a second electrode, where the buffer layer and spacer are formed simultaneously using a single mask process, reducing the number of manufacturing steps and improving light emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate processes are used to form the buffer layer and spacer, then each component can be optimized independently, but the manufacturing complexity and number of steps increase
Solution Approach 1:
The buffer layer and spacer are formed simultaneously in a single deposition process using the same mask pattern, combining two separate fabrication steps into one. This reduces the total number of manufacturing steps while maintaining the ability to optimize both components' dimensions and positions through unified process parameters.
2Use of energy by moving object
If the organic light-emitting layer is formed with a thin film of about 1000 Å, then light efficiency is improved, but the defect rate increases due to foreign substances during formation
Solution Approach 1:
The buffer layer is formed in advance before the organic light-emitting layer, creating a protective foundation that prevents foreign substance contamination during subsequent deposition steps. This preliminary protective layer allows the organic layer to be formed with optimal thin film thickness for light efficiency while maintaining high yield by preventing defects during the formation process.
3Illumination intensity
If the aperture is increased to improve light output, then light efficiency improves, but the stability and precision of the display device decreases
Solution Approach 1:
The spacer is designed with localized thickness variations, being thicker at specific regions to provide structural support and maintain aperture stability, while other regions have optimized thickness for light emission. This local differentiation allows the aperture to be sufficiently large for high light output while maintaining manufacturing precision through strategic structural reinforcement.
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 production yield, reduces defect rates, and simplifies the fabrication process, leading to improved light efficiency and the ability to produce high-resolution displays with reduced manufacturing costs and complexity.
Implementation Method 1
An electro-luminescence display device generates light based on the principle of electroluminescence. An exciton, which consists of an excited electron-hole pair, is generated inside an emissive layer, and when the exciton's electron and hole combine, a photon can be emitted.
Data Source
AI summary
An organic electro-luminance display device includes a first substrate including a plurality of sub-pixels, a first electrode on the first substrate, a buffer layer on the first electrode of a region that partitions each of the sub-pixels, a spacer on the buffer layer, the buffer layer and the spacer being integrally formed, an organic light-emitting layer on the first electrode that corresponds to each of the sub-pixels and the spacer, and a second electrode on the organic light-emitting layer.