OLED Common Layer Uniformity via Solvent Mediator
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Solution Overview
Problem
Existing methods for manufacturing organic light-emitting diode (OLED) displays face challenges in forming a uniform common layer during the deposition of the organic emission member, particularly when using a bank structure.
Innovation Solution
A method involving the sequential deposition of a solvent layer and an organic solvent layer on a pixel definition layer, where the solvent layer is removed through controlled drying, allowing the organic layer to form a uniform film that contacts both the pixel definition layer and the first electrode, enabling a uniform common layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a bank structure is used for organizing pixels, then device complexity is reduced and manufacturing is simplified, but the organic layer becomes difficult to form uniformly across the surface
Solution Approach 1:
The patent introduces a common layer as an intermediary material between the bank structure and the organic emission layer. This common layer has specific properties (solvent compatibility, surface energy) that enable the organic layer to spread uniformly across the complex bank structure, resolving the contradiction between simplified device architecture and manufacturing precision
Solution Approach 2:
The patent modifies the surface properties of the bank structure by depositing the common layer, which changes parameters such as surface energy, wettability, and chemical composition. These parameter changes enable subsequent organic layer deposition to achieve uniformity despite the underlying complex bank structure
2Ease of manufacture
If the organic emission member is deposited directly on the bank structure, then the manufacturing process is simplified, but the organic layer cannot form a uniform film
Solution Approach 1:
The patent applies the preliminary action principle by depositing the common layer before the organic emission layer. This preliminary layer preparation modifies the substrate surface to ensure subsequent organic material deposition achieves uniform film formation, maintaining ease of manufacture while improving precision
Solution Approach 2:
The common layer serves as a mediator between the bank structure and organic emission layer, providing intermediate surface properties that facilitate uniform organic layer formation without complicating the overall manufacturing process
3Reliability
If the organic layer is formed to contact both the pixel definition layer and first electrode, then device reliability is improved, but the manufacturing precision requirement increases
Solution Approach 1:
The common layer acts as an intermediary that extends over the pixel definition layer and first electrode, providing a continuous surface that guides the organic layer to contact both structures reliably, reducing positioning precision requirements while maintaining electrical contact reliability
Solution Approach 2:
The patent uses the dimensional approach by having the common layer extend in multiple directions and overlap different structures (pixel definition layer and first electrode), creating a three-dimensional arrangement that ensures organic layer contact with both components without requiring extreme positioning precision
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 method ensures a uniform organic layer formation, even in complex bank structures, enhancing the surface characteristics and uniformity of the OLED display.
Implementation Method 1
drying the organic solvent layer at a temperature in a first temperature range to form the organic layer in a form of a film
Implementation Method 2
drying the solvent layer at a temperature in a second temperature range
Data Source
AI summary
A method of manufacturing an organic light-emitting diode display includes disposing a first electrode on a substrate on which a plurality of transistors is disposed, disposing a pixel definition layer on the substrate to cover a part of the first electrode, disposing a solvent layer on the first electrode, disposing an organic layer on the pixel definition layer and the solvent layer, removing the solvent layer and disposing a second electrode on the organic layer.