OLED Pixel Defining Layer Ink Jet Groove Formation
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Solution Overview
Problem
Current OLEDs using ink jet printing technology face issues with non-uniform thickness of organic thin films and complex preparation processes for pixel defining layers, leading to long production cycles and high costs.
Innovation Solution
A method for preparing a pixel defining layer involving a substrate with a first defining pattern formed by ink jet printing a high surface energy material, followed by a drying treatment to create a concave accommodation groove, and a second defining pattern formed within this groove using a material with lower surface energy, eliminating the need for double masking and simplifying the preparation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pixel defining layer with a particular structure is used to define the thickness of thin film formed by ink jet printing, then the thickness uniformity of the organic thin film is improved, but the preparation process becomes complex requiring double masking and double exposure processes
Solution Approach 1:
The pixel defining layer is segmented into two distinct patterns: a first defining pattern formed by ink jet printing that creates a concave accommodation groove, and a second defining pattern formed by vacuum evaporation that fills the groove. This segmentation allows each pattern to serve a specific function - the first pattern defines the groove structure while the second pattern provides the final thickness definition, thereby simplifying the overall preparation process while maintaining thickness uniformity
Solution Approach 2:
The first defining pattern is formed in advance through ink jet printing to create the concave accommodation groove structure before the second defining pattern is added. This preliminary action establishes the foundational structure that guides subsequent material deposition, eliminating the need for complex double masking and double exposure processes while ensuring proper thickness control
2Manufacturing precision
If a pixel defining layer with a particular structure is used to define the thickness of thin film, then the thickness uniformity is improved, but the production cycle becomes long
Solution Approach 1:
The preparation process is segmented into two independent stages: first, ink jet printing to form the concave accommodation groove; second, vacuum evaporation to form the second defining pattern. This segmentation allows each stage to be optimized independently and eliminates the need for time-consuming double masking and double exposure operations, thereby reducing the overall production cycle while maintaining thickness uniformity
Solution Approach 2:
The mechanical masking and exposure system is replaced with a combination of ink jet printing and vacuum evaporation. This substitution eliminates the complex mechanical operations of double masking and double exposure, significantly reducing the production cycle time while achieving the same thickness control objective
3Manufacturing precision
If a pixel defining layer with a particular structure is used to define the thickness of thin film, then the thickness uniformity is improved, but the production cost becomes high
Solution Approach 1:
The complex mechanical masking and exposure system is replaced with ink jet printing technology combined with vacuum evaporation. This substitution eliminates the need for expensive double masking and double exposure equipment and processes, reducing production costs while maintaining the ability to achieve uniform thin film thickness
Solution Approach 2:
The preparation method changes from a photochemical process (masking and exposure) to a direct material deposition process (ink jet printing followed by vacuum evaporation). This parameter change in the manufacturing approach simplifies the process steps, reduces equipment requirements, and lowers production costs while achieving the same thickness control precision
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 precise control of thin film thickness, reduces production costs, and improves alignment accuracy, resulting in a more efficient and cost-effective OLED production process.
Implementation Method 1
The first defining pattern has a first surface energy, and the second defining pattern has a second surface energy, wherein the first surface energy is higher than the second surface energy
Implementation Method 2
forming a concave accommodation groove, the concave accommodation groove constituting the first defining pattern; the concave accommodation groove is formed by ink jet printing the first material to form the first defining pattern layer in a predetermined region of the substrate, and then subjecting the first defining pattern layer to a drying treatment
Data Source
AI summary
Preparation methods for a pixel defining layer and an OLED, a pixel defining element, an OLED, and a display device are disclosed. The method for preparing a pixel defining layer comprises: providing a substrate; forming a first defining pattern on the substrate, wherein the first defining pattern is composed of a concave accommodation groove, and the concave accommodation groove is formed by ink jet printing a first material, forming a first defining pattern layer in a predetermined region of the substrate, and then subjecting the first defining pattern layer to a drying treatment; forming a second defining pattern by ink jet printing a second material in the concave accommodation groove, wherein the first defining pattern and the second defining pattern constitute the pixel defining layer.