Solvent-Resistant Organic Layer for OLED Wet Process
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Solution Overview
Problem
The wet process used in manufacturing organic light emitting diode (OLED) devices faces challenges in forming hole injection and hole transport layers due to solvent compatibility issues, leading to decreased light emitting efficiency and lifespan, and difficulties in selecting suitable materials and solvents for these layers.
Innovation Solution
The use of a compound represented by Formula R1−(R2)n, where R1 is a diamine, arylene diamine, carbazole, or spiro-arylene diamine derivative, and R2 includes a C1 to C10 compound with an oxetane group, which forms a solvent-resistant organic layer that can be used as a hole injection or transport layer, enabling efficient light emission and extended device lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wet process is used to form multiple organic layers, then manufacturing simplicity and suitability for mass production are improved, but solvent compatibility issues cause layers to dissolve or swell, decreasing light emitting efficiency and lifespan
Solution Approach 1:
The patent modifies the chemical structure of the organic layer materials by introducing specific functional groups and molecular weight ranges (1,000-1,000,000 g/mol) to achieve appropriate solubility and cross-linking behavior. This parameter optimization allows the organic layers to be formed via wet process while maintaining stability against solvent dissolution, thereby resolving the contradiction between manufacturing simplicity and device reliability
Solution Approach 2:
The patent employs composite organic layer structures where different organic materials with complementary properties are combined. The first organic layer uses materials soluble in the first solvent, while the second organic layer uses materials soluble in the second solvent but insoluble in the first solvent. This composite approach enables sequential wet process formation without mutual dissolution, maintaining both ease of manufacture and device performance
2Device complexity
If the wet process is used for forming multiple organic layers, then equipment cost and process complexity are reduced, but material selection becomes more difficult due to solvent compatibility constraints
Solution Approach 1:
The patent establishes specific parameter ranges for organic materials including molecular weight (1,000-1,000,000 g/mol), solubility characteristics, and functional group composition. These parameter specifications create a standardized framework that simplifies material selection while ensuring compatibility with the wet process methodology, thereby reducing process complexity without limiting material versatility
Solution Approach 2:
The patent develops a universal wet process methodology that can be applied to form multiple types of organic layers (electron transporting, hole transporting, emitting layers) using the same basic procedure. The method accommodates various materials within defined parameter ranges, making the process universally applicable across different OLED device designs and reducing the need for specialized procedures for each material type
3Reliability
If solvents with high volatility and selective solubility are used, then layer stability is improved, but manufacturing efficiency and scalability to larger substrates are reduced
Solution Approach 1:
The patent optimizes solvent parameters including volatility, solubility characteristics, and evaporation rates to achieve balanced performance. The selected solvents provide sufficient layer stability during formation while maintaining reasonable evaporation rates for efficient processing. This parameter optimization enables the wet process to be applied to large substrates without compromising layer quality, thereby improving manufacturing efficiency while maintaining layer stability
Solution Approach 2:
The patent utilizes liquid solvent delivery systems (hydraulic approach) instead of vacuum deposition methods. This allows for uniform coating over large substrate areas through techniques such as spin coating, dip coating, or spray coating, significantly improving manufacturing efficiency and scalability while the solvent parameters are optimized to maintain layer stability during and after the coating process
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 enhances the light emitting efficiency and lifespan of OLED devices while allowing for mass production on larger substrates using a simple wet process, improving manufacturing efficiency and reducing material selection complexities.
Implementation Method 1
R2 is one of C1 to C10 compounds including an oxetane group... the organic layer is formed of a compound... which forms a solvent-resistant organic layer
Implementation Method 2
electrons and holes are supplied from the cathode and the anode to the organic light emitting layer and are recombined with each other. Then, light is emitted from the organic light emitting layer as the energy level of the electrons is changed from an unstable state (an excited state) to a stable state
Data Source
AI summary
An organic light emitting diode device includes an organic layer formed of a hole transport material or a hole injection material having a photocurable group. Therefore, the organic light emitting diode device can be formed using a wet process that is simple and can be used for a large substrate. Furthermore, the organic layer and an organic light emitting layer are less affected by a solvent. Thus, the lifespan of the organic light emitting diode device is increased and there is more freedom in selecting materials for the organic layer and the organic light emitting layer. A method of manufacturing the organic light emitting diode device is also disclosed.