OLED Electron Transporting Emission Layers and Integrated Mask Manufacturing
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Solution Overview
Problem
Conventional organic light emitting devices (OLEDs) are complex to manufacture and incur material loss during deposition, making them unsuitable for mass production.
Innovation Solution
The OLED structure includes an electron transporting-red emission layer, an electron transporting-green emission layer, and an electron transporting-blue emission layer, which cover all subpixels, and a method of forming these layers using specific masks to reduce the number of masking processes, thereby simplifying the manufacturing process and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional OLED manufacturing processes are used with multiple separate deposition masks for each emission layer, then manufacturing precision can be maintained, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple separate deposition masks (red emission layer mask, green emission layer mask, blue emission layer mask) into a single integrated mask structure. This single mask contains all necessary opening patterns for forming red, green, and blue emission layers simultaneously, thereby reducing the number of masking operations from three separate processes to one unified process, which directly reduces device complexity while maintaining manufacturing precision
Solution Approach 2:
The single integrated mask serves multiple functions: it defines patterns for red emission layers, green emission layers, and blue emission layers all at once. This multi-functional mask replaces what would traditionally require three separate specialized masks, each handling only one color channel, thus simplifying the overall manufacturing system while preserving the ability to precisely control each emission layer's pattern
2Manufacturing precision
If conventional OLED manufacturing processes are used with multiple separate deposition masks, then emission layer coverage can be ensured, but material loss during deposition increases
Solution Approach 1:
By merging multiple deposition steps into a single deposition process using the integrated mask, the patent eliminates material waste that occurs during intermediate steps. When multiple separate masks are used, materials deposited for one layer may be contaminated or wasted during subsequent mask changes and additional deposition processes. The single mask approach ensures all emission layer materials are deposited in one continuous operation, maximizing material utilization
Solution Approach 2:
The integrated mask is designed in advance with all necessary opening patterns pre-configured for red, green, and blue emission layers. This preliminary design allows a single deposition process to simultaneously form all emission layer patterns without requiring intermediate mask changes or additional deposition steps, thereby preventing material loss that would occur during multiple sequential deposition operations
3Manufacturing precision
If conventional OLED structures are used with separate handling of each subpixel layer, then emission characteristics can be optimized, but productivity decreases
Solution Approach 1:
The patent merges the formation of red, green, and blue emission layers into a single simultaneous deposition process using the integrated mask. This approach maintains the ability to optimize each emission layer's emission characteristics through precise pattern definition while dramatically improving productivity by reducing the number of separate manufacturing operations from three to one, thereby increasing manufacturing throughput
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 allows for the production of OLEDs with high yields and low costs, while maintaining excellent emission characteristics and extended lifetime.
Implementation Method 1
an electron transporting-red emission layer for emitting red light, an electron transporting-green emission layer for emitting green light, or an electron transporting-blue emission layer for emitting blue light
Data Source
AI summary
Organic light emitting devices including an electron transport-emission layer, and methods of preparing the same are included. The electron transport-emission layer may be an electron transport-red emission layer, an electron transport-green emission layer or an electron transport-blue emission layer. The methods produce high yields of the organic light emitting devices and are less expensive than conventional methods.