OELD Separator Molded Resin Width Variation

Solution Overview

Problem

The existing fabrication processes for organic electroluminescent display (OELD) devices require multiple mask processes, leading to increased production costs, longer processing times, and lower yields due to the complexity and number of steps involved.

Innovation Solution

A method is introduced that forms a separator using a mold with alternating recessed and protruding portions, allowing for the creation of a resin solution layer that solidifies into a separator with varying widths, which functions as both a buffer and a separator, reducing the need for additional mask processes and simplifying the fabrication process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple mask processes are used to form separator and buffer layer, then manufacturing precision is improved, but device complexity and processing time increase

Engineering Contradiction:

Improveseparator formation precisionVSAvoidfabrication process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The separator and buffer layer are formed as a single integrated structure using one mold process, combining two previously separate functions into one component. This reduces the number of fabrication steps while maintaining the precision needed for both separation and buffering functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mold is designed with pre-defined recessed and protruding portions that automatically create the separator and buffer layer structures during a single coating and solidification process, eliminating the need for subsequent mask-based patterning steps.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If multiple mask processes are used to form separator and buffer layer, then manufacturing precision is improved, but productivity decreases

Engineering Contradiction:

Improveseparator formation precisionVSAvoidfabrication throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The separator and buffer layer are formed as a single integrated structure using one mold process, combining two previously separate functions into one component. This reduces the number of fabrication steps while maintaining the precision needed for both separation and buffering functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The resin solution is coated and solidified in a continuous process without interruption for multiple mask applications, significantly reducing processing time and improving fabrication throughput while maintaining structural precision.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If multiple mask processes are used to form separator and buffer layer, then manufacturing precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improveseparator formation precisionVSAvoidfabrication cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The separator and buffer layer are formed as a single integrated structure using one mold process, combining two previously separate functions into one component. This reduces the number of fabrication steps while maintaining the precision needed for both separation and buffering functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The complex multi-step mask process is replaced by extracting the essential patterning function into a single mold component, simplifying the fabrication process while achieving the required structural precision.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of manufacture

If separator has uniform width, then ease of manufacture is improved, but functional performance deteriorates

Engineering Contradiction:

Improveseparator fabrication simplicityVSAvoidbuffer and separator function

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The separator is designed with asymmetric width variation - wider at the base for buffering and narrower at the top for separation - allowing each portion to optimize its function while being formed in a single mold process.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

Different portions of the separator have different widths tailored to their specific functions: the lower portion has greater width for electrical buffering, while the upper portion has reduced width for effective light separation, with each region optimized for its role.

Inventive Principle:

Principle #3Local quality

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 fabrication processing time and cost by eliminating the need for multiple mask processes, improving production yield and enabling more efficient manufacturing of OELD devices.

Implementation Method 1

solidifying the resin solution layer by heating

Methodology Applied

Scientific EffectSolidification: Phase Change

Data Source

PatentUS7728509B2Organic electroluminescent display device and method of fabricating the same

Publication Date: 2010.06.01 LG DISPLAY CO LTD

AI summary

An organic electroluminescent display device comprises a substrate, including a pixel region and a non-pixel region at a boundary of the pixel region; a first electrode on the substrate in the pixel region; a separator over the first electrode, the separator located in the non-pixel region, the separator including a first portion having a first width and a second portion having a second width smaller than the first width, the first portion overlapping edges of the first electrode, and the second portion within the non-pixel region; an organic electroluminescent layer over the separator in the pixel region surrounded by the separator; and a second electrode on an entire surface of the organic electroluminescent layer and the separator.