OLED Micro Cavity Emission Layers
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Solution Overview
Problem
Current organic light emitting device manufacturing processes are complex and inefficient, leading to increased power consumption and reduced reliability due to the need for multiple fine metal masks and thick emission layers, which also result in mask rib issues and poor emission efficiency.
Innovation Solution
The organic light emitting device structure simplifies the manufacturing process by using common emission layers for all sub-pixel areas with a first-order optical distance, reducing the number of fine metal masks required and lowering the thickness of hole transporting and emission layers, thereby reducing power consumption and improving emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick emission layers and second-order optical distance are used to improve emission efficiency, then emission efficiency is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent changes the optical distance parameter from second-order to first-order, which fundamentally alters the thickness requirements of the emission layers. This parameter change enables the use of thinner layers while maintaining or improving emission efficiency, thereby reducing device complexity and manufacturing difficulty.
2Reliability
If multiple fine metal masks are used to pattern emission layers by area, then emission efficiency is improved, but manufacturing complexity and productivity are reduced
Solution Approach 1:
The patent extracts and eliminates the fine metal masks from the manufacturing process by adopting a different patterning approach based on first-order optical distance, which inherently provides better emission efficiency without requiring complex masking steps.
Solution Approach 2:
The patent replaces the mechanical masking system with an optical field-based approach where the first-order optical distance creates the necessary emission patterns without physical masks, thereby simplifying manufacturing and improving productivity.
3Illumination intensity
If current is increased to achieve higher brightness, then brightness is improved, but power consumption increases and reliability decreases
Solution Approach 1:
The patent changes the optical distance parameter to first-order, which improves the optical field distribution and emission efficiency. This allows the device to achieve higher brightness at lower current levels, thereby reducing power consumption and improving reliability.
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 more efficient and cost-effective manufacturing process with improved emission efficiency and reduced power consumption, as well as preventing mask rib issues, by forming red, green, and blue emission layers as common layers with a first-order optical distance, allowing for lower driving voltages and enhanced light emission.
Implementation Method 1
emission efficiency of the organic light emitting device may be improved by adjusting thicknesses of the first and second hole transporting layer 125 and 130 and the organic emission layers 135, 140 and 145 in the respective sub-pixel areas to produce a micro cavity effect
Data Source
AI summary
An OLED (Organic Light Emitting Diode) device can include a red emission layer, a green emission layer, and a blue emission layer which are non-patterned and stacked as common layers configured such that a thickness of each of a hole transporting layer, the red emission layer, the green emission layer, and the blue emission layer is respectively less than those corresponding layers in a conventional OLED device having a red emission layer, a green emission layer, and a blue emission layer which are patterned.