Organic Light Emitting Device Solid-State Film Formation
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Solution Overview
Problem
Organic light emitting devices face issues with thickness mura in the organic film due to surface tension of liquid materials used in manufacturing, which affects the uniformity and quality of the film.
Innovation Solution
The use of solid organic materials with different melting points, specifically fatty acid compounds, is employed to form multiple active layers in the organic compound layer, where each layer is hot-melted and coated sequentially to avoid the issues of surface tension and thickness mura, with the melting points of the layers decreasing from the anode to the cathode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid materials are used to form the organic film through inkjet injection, then the manufacturing process is simple and efficient, but thickness mura occurs due to surface tension of the liquid materials
Solution Approach 1:
The patent changes the physical state parameter of the organic material from liquid to solid form. By using solid organic materials instead of liquid materials, the surface tension issue that causes thickness mura is eliminated while maintaining the inkjet injection manufacturing process
Solution Approach 2:
The patent employs composite organic materials with specific molecular structures that enable solid-state materials to be processed through inkjet injection. The composite nature of these materials allows them to exhibit both solid-state properties (no surface tension) and processability (can be injected and formed into films)
2Adaptability or versatility
If multiple active layers are formed to enable three primary color light emission, then the device can emit three primary colors, but the device complexity increases
Solution Approach 1:
The patent divides the organic compound layer into multiple active layers, with each layer responsible for emitting one of the three primary colors. This segmentation allows independent optimization of each layer's material composition and thickness to achieve precise color control
Solution Approach 2:
The patent transitions from a single-layer structure to a multi-layer vertical structure. By stacking multiple active layers in the vertical dimension, the device achieves three primary color emission capability without significantly increasing lateral device footprint
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 method ensures that the organic compound layer is formed without thickness mura, maintaining uniformity and quality, and allows for efficient light emission with reduced power consumption and smaller device size.
Implementation Method 1
The use of solid organic materials with different melting points, specifically fatty acid compounds, is employed to form multiple active layers in the organic compound layer, where each layer is hot-melted and coated sequentially
Data Source
AI summary
A method of manufacturing an organic light emitting device includes providing a substrate and forming an anode on the substrate; melting at least two organic materials having different melting points by a heating means; and coating and cooling each of the melted at least two organic materials on a surface of the anode respectively, in sequence, to form an organic compound layer having at least active layer. A melting point of one of the at least two active layers adjacent to the anode is greater than a melting point of another of the at least two active layers away from the anode.