OLED Pixel Definition via Capillary Frame Structures
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Solution Overview
Problem
Existing methods for manufacturing organic electroluminescent display devices face challenges in forming high-definition, large-sized displays with precise color pixel formation, as they require high-precision evaporation masks and ink-jet methods that are complex and costly, leading to issues with material efficiency and throughput.
Innovation Solution
The use of frame-like structures outside the display area to facilitate the flow of coating liquids into pixel regions within the display area through capillarity, allowing for the separate coating of multiple colors without the need for evaporation masks, thereby simplifying the manufacturing process and improving material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mask evaporation method is used to form separate color pixels, then manufacturing precision of pixel boundaries is improved, but device complexity and manufacturing cost increase due to high-precision mask requirements
Solution Approach 1:
The patent extracts the mask system from the manufacturing process entirely. Instead of using complex evaporation masks to define pixel boundaries, the invention uses direct ink-jet printing to deposit color conversion materials precisely at target locations, eliminating the mask component and its associated complexity while maintaining manufacturing precision
Solution Approach 2:
The patent replaces the mechanical mask system with a digital printing system. The ink-jet method uses computer-controlled droplet deposition to define pixel boundaries, substituting mechanical mask alignment and positioning with digital positioning and control, thereby reducing device complexity while maintaining or improving precision
2Device complexity
If ink-jet method is used to form separate color pixels, then device complexity is reduced, but manufacturing precision deteriorates due to coating variability
Solution Approach 1:
The patent introduces a color conversion material layer as an intermediary between the white light emitting layer and the color filter. This layer converts broad-spectrum light into specific wavelengths, enabling precise color control through material selection rather than relying solely on precise coating thickness control, thereby improving manufacturing precision while maintaining process simplicity
Solution Approach 2:
The patent changes the approach from controlling color through coating thickness parameters to controlling color through material composition parameters. By selecting specific color conversion materials with defined emission characteristics, the system achieves precise color control without requiring extremely uniform coating thickness, thus improving manufacturing precision while keeping the process simple
3Manufacturing precision
If high-precision evaporation masks are used for large substrate sizes, then manufacturing precision is maintained, but weight of masking system increases
Solution Approach 1:
The patent removes the heavy evaporation mask system entirely from the manufacturing process. By using direct ink-jet printing, the system eliminates the need for large, rigid masks that would be required to maintain precision on large substrates, thereby dramatically reducing the weight of stationary objects while preserving pixel alignment accuracy through digital positioning
4Manufacturing precision
If conventional methods are used for high-definition displays, then manufacturing precision is achieved, but productivity decreases due to complex processes
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated process. The ink-jet method simultaneously deposits organic EL materials, color conversion materials, and patterning in one pass, eliminating the need for separate evaporation, masking, and coating steps. This merging of operations maintains color pixel definition while significantly improving manufacturing throughput and 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 enables the cost-effective and efficient manufacturing of high-definition organic EL display devices with reduced pixel region sizes, allowing for the simultaneous coating of multiple colors without the complexity and precision issues of traditional methods, thereby enhancing manufacturing throughput and reducing costs.
Implementation Method 1
The use of frame-like structures outside the display area to facilitate the flow of coating liquids into pixel regions within the display area through capillarity
Data Source
AI summary
An OLED comprising a substrate with a plurality of pixel regions of first to third colors disposed within a display area, and a functional material layer comprising an organic emissive layer disposed at each of the plurality of pixel regions, wherein first to third partition parts are disposed on the substrate within the display area, first to third frame-like structures are disposed on the substrate outside the display area, the pixel region of the first color is disposed within a first demarcation region demarcated by the first partition part, the pixel region of the second color is disposed within a second demarcation region demarcated by the second partition part, the pixel region of the third color is disposed within a third demarcation region demarcated by the third partition part, and the first to third demarcation regions are connected to the to the interior of the first to third frame-like structures, respectively.