OLED Substrate High Refractive Scattering Layer Planarization
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Solution Overview
Problem
Current substrates for organic light-emitting diodes face challenges in achieving high light extraction efficiency and uniform light emission while maintaining low production and material costs, with existing methods often resulting in non-uniform thickness and mechanical instability due to the use of high refractive materials.
Innovation Solution
A substrate with a base substrate, a high refractive scattering layer containing scattering particles immersed in a high refractive material, and an adhesive layer for laminating the base substrate and scattering layer, where the scattering layer has unevenness on one surface and a planarized surface on the other, enhancing light extraction and facilitating mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a high refractive material is deposited on an uneven surface to increase light extraction efficiency, then light extraction efficiency is improved, but the thickness becomes non-uniform and electrical stability deteriorates
Solution Approach 1:
The patent applies preliminary planarization by forming a planarized surface layer on the uneven substrate before depositing the organic material layer. This preliminary action creates a flat foundation that ensures uniform thickness of subsequent layers while maintaining the light scattering benefits of the underlying uneven structure.
Solution Approach 2:
The substrate structure is segmented into distinct functional layers: an uneven base layer for light scattering, a planarized intermediate layer for surface flatness, and the organic material layer for device functionality. This segmentation allows each layer to optimize its specific function without compromising the others.
2Manufacturing precision
If the thickness of the planarized surface is increased to improve planarization, then surface flatness is improved, but mechanical strength decreases and light transmission is reduced
Solution Approach 1:
The patent applies local quality by creating a planarized surface layer with specific properties ( adequate thickness for flatness but not excessive to maintain strength and transmission). The planarization is localized to only where needed on the substrate surface, maintaining the uneven light-scattering properties in other regions.
3Loss of energy
If wet coating is performed on an uneven surface to form a high refractive layer, then light scattering is improved, but the surface becomes wave-shaped and uniformity deteriorates
Solution Approach 1:
The patent performs preliminary planarization by forming a planarized surface layer before final device deposition. This preliminary action prevents the wave-shaped surface formation that would occur with direct wet coating on uneven surfaces, while still allowing light scattering from the underlying structure.
4Manufacturing precision
If polishing is used to achieve uniform thickness after thick deposition, then thickness uniformity is improved, but production cost and complexity increase
Solution Approach 1:
The patent performs preliminary planarization during the deposition process itself by controlling the formation of the planarized surface layer, avoiding the need for post-deposition polishing operations. This preliminary action simplifies the manufacturing process while achieving the required thickness uniformity.
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 improves light extraction efficiency, achieves excellent planarization, and reduces production costs without degrading the diode's performance, enabling the manufacture of high-performance organic light-emitting diodes with enhanced luminance and durability.
Implementation Method 1
a high refractive scattering layer formed on the base substrate and comprising scattering particle scattering light in a high refractive material
Data Source
AI summary
Provided is a substrate for an organic light emitting diode including a base substrate, a high refractive scattering layer formed on the base substrate, and having a scattering particle scattering light in a high refractive material, and an adhesive layer formed between the base substrate and the high refractive scattering layer to laminate the base substrate with the high refractive scattering layer, wherein the high refractive scattering layer has a structure in which the scattering particle is immersed in the high refractive material, an average thickness of the high refractive scattering layer is smaller than an average diameter of the scattering particle, a surface of the high refractive scattering layer laminated with the base substrate by the adhesive layer has unevenness formed by the scattering particle, the opposite surface of the high refractive scattering layer laminated with the base substrate by the adhesive layer has a planarized surface, and a method for manufacturing the same. The substrate may have an excellent degree of planarization and improved light extraction efficiency without degradation in performance of the diode, and low process and material costs and mass-production of the substrate may be easily achieved.