Organic Light-Emitting Display Device with Segmented Emission Layers
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Solution Overview
Problem
The challenge in manufacturing high-resolution organic light-emitting display devices is the reduction in the life of the emitting layers, particularly the green light-emitting layer, due to heat generated from laser beams used in the transfer process, and the difficulty in creating fine patterns with masks.
Innovation Solution
The solution involves forming at least two emitting layers as common layers over the entire substrate surface using a combination of deposition and transfer processes, where the second emitting layer is formed using a deposition process to minimize heat exposure, and auxiliary layers are used to control light resonance and enhance color purity, reducing the need for fine metal masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a transfer method using a laser is used to pattern the organic layer, then fine patterns can be formed relatively easily, but heat generated from laser beams directly affects the emitting layer, reducing the life of the organic light-emitting display device
Solution Approach 1:
The organic layer is divided into multiple emitting layers (first emitting layer, second emitting layer, third emitting layer) with different functions. The first and third emitting layers are formed by transfer method using laser for high precision patterning, while the second emitting layer is formed by deposition method to avoid laser heat damage, thus resolving the contradiction between pattern precision and device life
Solution Approach 2:
Different formation methods are applied to different emitting layers based on their specific requirements. The first and third emitting layers require precise patterning so they are formed by transfer method, while the second emitting layer is formed by deposition method to minimize heat exposure,实现ing local optimization of both precision and durability
2Productivity
If a deposition method using a mask is used to pattern the organic layer, then high efficiency and stability are ensured, but it has become difficult to manufacture a mask including an opening that corresponds to the fine pattern
Solution Approach 1:
The organic layer is segmented into multiple emitting layers formed by different methods. The first and third emitting layers use transfer method for fine patterns, while the second emitting layer uses deposition method for high efficiency, thus combining the advantages of both approaches
Solution Approach 2:
A buffer layer is introduced as an intermediary between the emitting layers and the substrate. This buffer layer facilitates the transfer process and enables the formation of fine patterns without requiring complex masks, thus resolving the contradiction between manufacturing efficiency and pattern 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 extends the life of the organic light-emitting display device, particularly the green light-emitting layer, while increasing process efficiency and reducing the driving voltage, and ensures high-resolution output.
Implementation Method 1
forming a plurality of emitting layers and a plurality of auxiliary layers on the first electrodes... at least two of the emitting layers are formed by a deposition process
Implementation Method 2
performing a transfer process on the third emitting layer by using a laser to transfer a first emitting layer and a first auxiliary layer onto the third emitting layer
Data Source
AI summary
An organic light-emitting display device includes a substrate which includes a plurality of areas, a plurality of first electrodes disposed on the areas of the substrate, respectively, a second electrode disposed on the first electrodes, and a plurality of emitting layers disposed between the first electrodes and the second electrode. At least two of the emitting layers are disposed on all of the areas.