OLED Organic Layer Edge Overlap to Suppress Leakage

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Solution Overview

Problem

In OLED display devices, misalignment of functional layers at the peripheral portion of the organic layer leads to performance degradation due to edge portions not being aligned, causing issues like increased energy consumption and electric leakage.

Innovation Solution

The implementation of a rib structure and specific layer configurations, including a first region with a higher dopant concentration and a second region with a lower concentration, along with carrier blocking layers, to cover the edge portions of the organic layers, thereby preventing direct contact with the second electrode and reducing leakage currents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If vacuum vapor deposition method is used to form organic layers, then the organic layers can be formed efficiently, but edge portions of functional layers may not be aligned at peripheral portions leading to performance degradation

Engineering Contradiction:

Improveorganic layer formation efficiencyVSAvoidedge alignment precision of functional layers

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent introduces a rib structure at the peripheral portions of the substrate that provides localized support and alignment reference for the organic layers. This rib structure has a specific height and width that creates a physical constraint, ensuring that edge portions of different functional layers are aligned at the peripheral portions while maintaining efficient vacuum vapor deposition formation of the organic layers.

Inventive Principle:

Principle #3Local quality

2Reliability

If functional layers are stacked with overlapping edges, then leakage currents are reduced, but device complexity increases

Engineering Contradiction:

Improveleakage current suppressionVSAvoidorganic layer structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The rib structure serves as an intermediary element that facilitates the overlapping edge configuration of functional layers. By providing a physical platform at the peripheral portions, the rib enables the second and third functional layers to overlap the first functional layer's edges, thereby suppressing leakage currents without requiring complex manufacturing processes or additional materials.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 configuration effectively suppresses performance degradation by minimizing leakage currents and energy consumption, enhancing the overall performance of the OLED display elements.

Implementation Method 1

Such organic layer is formed, for example, by a vacuum vapor deposition method

Methodology Applied

Scientific EffectVacuum vapor deposition: Physical Vapour Deposition

Data Source

PatentUS12477898B2OLED including organic layers including overlapping edges

Publication Date: 2025.11.18 MAGNOLIA WHITE CORP

AI summary

According to one embodiment, a display device includes a first electrode, an organic layer disposed on the first electrode, and a second electrode covering the organic layer. The organic layer includes a first layer having a first edge portion and a second layer between the first layer and the second electrode. The second layer covers the first edge portion.