OLED Organic Layer Uniformity via Dual-Solvent Pre-treatment
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Solution Overview
Problem
The existing methods for manufacturing OLED displays face challenges in achieving uniform thickness of the organic layer due to varying drying conditions across the ink droplets, leading to non-uniform organic layers.
Innovation Solution
A method involving the use of a first solvent with a lower boiling point and a second solvent, or sub-solvents with different boiling points, is applied to create uniform vaporization conditions by pre-treating the electrode with the first solvent before applying the ink containing organic material, ensuring consistent drying and layer formation across the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ink is dropped directly on the pixel electrode and dried, then the organic layer is formed, but the thickness of the organic layer is not uniform due to varying drying conditions between center and circumference
Solution Approach 1:
The patent applies preliminary action by pre-treating the pixel electrode with a first solvent (such as water or alcohol) before dropping the ink. This pre-treatment ensures that the substrate is already wet when the ink is applied, eliminating the need for complex drying control and enabling uniform organic layer formation through subsequent uniform drying conditions.
Solution Approach 2:
The patent introduces an intermediary substance (first solvent) between the ink and the pixel electrode. This intermediary layer mediates the drying process by providing a uniform medium that evaporates consistently across the entire ink droplet surface, preventing the non-uniform drying that occurs when ink is dropped directly on the electrode.
2Manufacturing precision
If a single solvent system is used in the ink, then the formulation is simple, but uniform vaporization conditions cannot be achieved across the ink droplet
Solution Approach 1:
The patent segments the solvent system into two distinct parts: a first solvent (water or alcohol) applied as pre-treatment and a second solvent (organic solvent) contained in the ink formulation. This segmentation allows each solvent to perform its specific function - the first solvent provides uniform wetting and the second solvent provides controlled vaporization - thereby achieving uniform vaporization conditions without requiring a complex single-solvent system.
Solution Approach 2:
The patent changes the physical parameters of the solvent system by using solvents with different boiling points and evaporation rates. The first solvent (lower boiling point) evaporates first to prepare the surface, while the second solvent (higher boiling point) provides sustained, uniform vaporization during the drying process, creating optimal conditions for uniform organic layer formation.
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 results in a uniform organic layer formation, enhancing the brightness and lifespan of the OLED display by maintaining consistent thickness and improving pixel filling characteristics.
Implementation Method 1
making vaporization conditions of ink uniform to form a uniform organic layer
Data Source
AI summary
A method of manufacturing a display device includes forming a thin film transistor on an insulating substrate, forming an electrode which is electrically connected with the thin film transistor, forming a wall which surrounds the electrode, supplying a first solvent to the electrode that is surrounded by the wall, and supplying ink which comprises an organic material and a second solvent to the electrode which has previously received the first solvent. Thus, the manufacturing method produces a display device which has a uniform organic layer.