Stacked Deposition Sources for OLED Uniformity
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Solution Overview
Problem
Existing organic light-emitting display devices face challenges in achieving high light-emission efficiency and patterning organic thin films on large areas due to variations in luminous efficiencies of red, green, and blue emissions, and difficulties in forming fine patterns, which limits the manufacturing of large-sized display devices with satisfactory characteristics.
Innovation Solution
A deposition source assembly and organic layer deposition apparatus that includes a first deposition source for host materials and a second deposition source for dopant materials, with nozzles arranged to ensure even deposition, and a patterning slit sheet to facilitate uniform doping and improved patterning, allowing for the formation of organic layers on substrates with enhanced characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single deposition source is used, then the device structure is simple, but the deposition uniformity and manufacturing precision deteriorate
Solution Approach 1:
The single deposition source is segmented into multiple deposition sources (first deposition source for host material, second deposition source for dopant material) that are stacked vertically. Each source has its own nozzle unit, allowing independent control of material deposition. This segmentation enables precise control over the deposition process while maintaining structural simplicity through the vertical stacking arrangement.
2Manufacturing precision
If multiple deposition sources are stacked, then the deposition uniformity improves, but the device complexity increases
Solution Approach 1:
The patent transitions from a horizontal arrangement of deposition sources to a vertical stacked configuration. The first and second deposition sources are arranged in the vertical dimension, with their respective nozzle units (first nozzle unit and second nozzle unit) positioned at different heights. This dimensional change allows multiple materials to be deposited simultaneously with improved uniformity while managing complexity through compact vertical integration.
3Productivity
If conventional deposition apparatus is used, then the manufacturing cost is low, but the productivity and manufacturing yield deteriorate
Solution Approach 1:
The stacked deposition sources enable continuous simultaneous deposition of host material and dopant material onto the substrate. The first deposition source and second deposition source operate concurrently, eliminating the need for sequential deposition processes. This continuous action improves manufacturing yield and productivity while the integrated design keeps manufacturing costs manageable.
4Area of stationary object
If organic thin films are patterned on large area, then the display device size increases, but the patterning precision and luminous efficiency deteriorate
Solution Approach 1:
The patent employs multiple nozzle units (first nozzle unit with multiple nozzles, second nozzle unit with multiple nozzles) that can be independently controlled. Each nozzle deposits material with precise local control, ensuring uniform deposition quality across the entire large-area substrate. This local quality control maintains patterning precision even as the substrate area increases.
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
The solution enables improved deposition efficiency and uniformity, resulting in enhanced color coordinates, luminous efficiency, driving voltage, and lifespan of organic light-emitting display devices, suitable for large-scale manufacturing.
Implementation Method 1
a deposition source for discharging a deposition material
Data Source
AI summary
A method of manufacturing an organic light-emitting display apparatus includes: disposing an organic layer deposition apparatus to be apart from a substrate by a set distance; and depositing deposition material on the substrate while the organic layer deposition apparatus or the substrate is moved relative to the other, the deposition source apparatus including: a deposition source including a first deposition source and a second deposition source stacked on the first deposition source; a deposition source nozzle unit including a second deposition source nozzle unit at a side of the second deposition source to face the substrate and including a plurality of second deposition source nozzles, and a first deposition source nozzle unit at the side of the second deposition source to face the substrate and including a plurality of first deposition source nozzles formed to pass through the second deposition source; and a patterning slit sheet smaller than the substrate.