Organic Electroluminescent Device with Controlled Microresonator Distances
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Solution Overview
Problem
The existing manufacturing processes for organic electroluminescent devices require multiple fine metal masks, increasing the complexity, cost, and reducing the yield of the production due to the numerous deposition processes involved.
Innovation Solution
The proposed solution involves an organic electroluminescent device with a reduced number of fine metal masks by using a method that includes a substrate with separate regions for red, green, and blue sub-pixels, where the optical microresonator distances are controlled to achieve selective constructive and destructive interference, allowing for the emission of specific wavelengths, and the device is manufactured using a method that forms the necessary layers with fewer fine metal masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple fine metal masks are used in the manufacturing process, then the precision of sub-pixel pattern formation is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple deposition processes into a single process by forming the blue light emitting layer and green light emitting layer simultaneously in one deposition step. This merging of operations eliminates the need for multiple fine metal masks while maintaining precise sub-pixel pattern formation, directly resolving the contradiction between manufacturing precision and device complexity
Solution Approach 2:
The patent creates a universal deposition process that can form multiple different light emitting layers (blue and green) with different optical microresonator distances in a single operation. This multi-functional approach allows one deposition process to replace what would traditionally require multiple separate processes and masks, reducing manufacturing complexity while maintaining precision
2Manufacturing precision
If multiple deposition processes are used, then the quality of light emitting layers is improved, but the productivity decreases
Solution Approach 1:
By merging the deposition of blue and green light emitting layers into a single process step, the patent eliminates multiple deposition operations that would sequentially reduce productivity. The simultaneous formation of both layers maintains quality control while improving production yield by reducing the number of process steps
Solution Approach 2:
The patent implements continuous deposition of multiple light emitting layers without interrupting the manufacturing process. This continuous action approach maintains high production throughput while ensuring consistent layer quality, as the deposition process operates continuously rather than being interrupted by multiple separate processing steps
3Manufacturing precision
If multiple fine metal masks are used, then the control over optical microresonator distance is improved, but the loss of time in manufacturing increases
Solution Approach 1:
The patent combines the formation of multiple light emitting layers with different optical microresonator distances into a single deposition process. This merging eliminates the time-consuming sequence of multiple mask alignments and deposits, reducing manufacturing cycle time while maintaining precise control over each layer's optical properties through the continuous deposition process
Solution Approach 2:
The patent performs preliminary patterning of the substrate into distinct red, green, and blue sub-pixel regions before the deposition process. This preliminary action allows subsequent deposition of multiple layers to occur simultaneously across different regions without requiring multiple masks, thereby reducing manufacturing time while maintaining precise spatial control over optical microresonator distances
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 reduces the number of deposition processes, improves the yield, and decreases the manufacturing costs of organic electroluminescent devices while maintaining the ability to produce full-colored images through the controlled emission of red, green, and blue light from each sub-pixel.
Implementation Method 1
an organic light emitting layer between the first electrode and the second electrode, which includes a blue light emitting layer and a green light emitting layer
Implementation Method 2
one of the first electrode or the second electrode includes a semitransparent material and an other one of the first electrode or the second electrode includes a light reflection material
Implementation Method 3
an optical microresonator distance is defined between the first electrode and the second electrode, and the optical microresonator distance of one of the red sub-pixel, the green sub-pixel, or the blue sub-pixel is different from the optical microresonator distance of other ones
Data Source
AI summary
An organic electroluminescent device includes a plurality of main pixels. Each of the main pixels includes red, green, and blue sub-pixels. Each of the sub-pixels includes a first electrode, a second electrode opposite to the first electrode, and an organic light emitting layer between the first and second electrode. The organic light emitting layer of each of the sub-pixels includes a blue light emitting layer and a green light emitting layer. Optical microresonator distances of the red, green, and blue sub-pixels are different from each other.