Organic Light-Emitting Device Insulating Layer Structure
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Solution Overview
Problem
Conventional organic light-emitting devices face issues with improper formation of organic films, such as the hole transport layer, over second banks, leading to potential low light-emission performance due to insufficient thickness and risk of leak currents.
Innovation Solution
The organic light-emitting device features a substrate with a first insulating layer and light-emitting portions that include a first electrode, an organic laminate with an organic light-emitting layer, and a second electrode, where the non-light-emitting portion between adjacent light-emitting portions has extension portions of the first electrodes and a second insulating layer, with the upper surface of the second insulating layer being lower than the first electrodes, reducing the risk of improper film formation and leak currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional structure with second banks is used to define light-emitting portions, then the device complexity is reduced and ease of manufacture is improved, but the organic film formation precision deteriorates leading to improper film formation over the second banks
Solution Approach 1:
The patent divides the insulating layer into multiple segments: a first insulating layer covering the second banks, and a second insulating layer filling the gaps between light-emitting portions. This segmentation allows each insulating layer to serve specific functions - the first layer provides structural support while the second layer ensures proper organic film formation in gap areas, thereby resolving the contradiction between manufacturing simplicity and film formation precision.
Solution Approach 2:
The patent introduces a second insulating layer as an intermediary structure that fills the gap areas between light-emitting portions. This intermediary layer acts as a mediator that prevents improper organic film formation in the gap regions while maintaining the overall simple bank-based structure, thus improving manufacturing precision without significantly increasing device complexity.
2Device complexity
If the organic film thickness is insufficient over the second banks, then the device complexity remains low, but the light-emission performance deteriorates due to low luminous efficacy and potential leak currents
Solution Approach 1:
The patent applies preliminary action by forming the first and second insulating layers before depositing the organic films. The first insulating layer is formed to cover the second banks, and the second insulating layer is formed to fill the gap areas. This preliminary structuring ensures that when organic films are subsequently deposited, they form uniformly with adequate thickness both over the light-emitting portions and the gap areas, preventing reliability issues without adding complex processing steps.
Solution Approach 2:
The patent applies local quality by giving different regions of the insulating structure different properties: the first insulating layer provides general insulation and structural support, while the second insulating layer specifically addresses the gap areas to ensure proper organic film formation. This localized differentiation ensures adequate organic film thickness where needed (over gap areas) while maintaining simple device structure overall, thus improving reliability without significantly increasing device complexity.
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 enhances the likelihood of proper organic film formation and reduces the risk of low light-emission performance, achieving high luminous efficacy by ensuring the organic laminate is formed correctly over the second insulating layer.
Implementation Method 1
an organic light-emitting layer 907
Data Source
AI summary
An organic light-emitting device having light-emitting portions arranged in two directions along a substrate main surface. Each light-emitting portion, in a first direction intersecting the substrate main surface, includes, disposed via a first insulating layer, a first electrode, an organic laminate, and a second electrode. In a second direction being one of the two directions along the substrate main surface, a non-light-emitting portion is present between adjacent light-emitting portions. The first electrodes of the adjacent light-emitting portions extend into the non-light-emitting portion. A second insulating layer is present between portions of the first electrodes in the non-light-emitting portion, and covers the portions of the first electrodes in the non-light-emitting portion. A height of the second insulating layer from the substrate main surface is lower than a height, from the substrate main surface, of upper surfaces of portions of the first electrodes in the light-emitting portions.